LF 45 - 55 PDF

Workshop manual LF 45/55 seriesWorkshop manuals LF45/55 series Overview OVERVIEW ‘The workshop manual overview sheet indicates the sub-division and index sheets that should be Present in this workshop manual. In addition, it gives the latest dates of issue. By means of this overview the workshop manual may be checked for completeness. Group — Sub-division/Contents Date Binder 1. ° Sub-division . 7 — 0201 Contents technical data. > 0201 Contents safety instructions and warnings 0201 Contents threaded connections a 0201 Contents seals and bearings : a. 0201 Contents general operations ce 0201 Contents paint treatment... on 0201 Contents conversion tables. oe. 0201 1 Sub-division 210 Contents technical data 0210 Contents diagnostics 0210 Contents internal cab components 0210 Contents cab heating .. 0210 Contents external cab components, ‘210 Contents cab suspension no : 0210 Contents cab titing gear : : 0210 Contents seats : 0210 Contents accessories 0210 2 ‘Sub- __LFA5/55 series Contents CONTENTS, Page Date 1. PRESERVATION AND DE-WAXING 4 0201 1.1 Preservation 4 0201 12 De-waxing 12 0201 2. CLEANING VEHICLES a4 0201 2.1 High-pressure cleaner a4 0201 © 0201 RBarGENERAL OPERATIONS 0 Contents LF45/S5 series = ~“ ~ ~ 2 DAE ©0201oO GENERAL OPERATIONS LF45/55 series 1. PRESERVATION AND DE-WAXING 1.1. PRESERVATION Note: Observe the applicable environmental requirements, 1. Clean the vehicle thoroughly so that all dirt and dust are removed. 2. Use pressurised air to remove any residues from the vehicle. 3. Coverall glazing, headlights and taillights, 4. Use a spray gunto spray undiluted preserving agent RUSAN 05018 (a FINA roduc) over the chassis frame and its fittings, all parts and components in the engine compartment and all painted sheet ‘metal parts. Tit the cab to be able to spray the preserving wax on the cab roof. Make sure that all edges, joints and cavities are sprayed with a “full jet” of preserving agent 5. Use a brush to apply Rusan D5018 to the wheel studs. on ne account spray reserving By eee fire ases, By wapeicessss Sense Deen es ©0201 DAE Preservation and de-waxing ooGENERAL OPERATIONS 0 Preservation and de-waxing LF45/55 series = 4.2 DE-WAXING Note: Observe the applicable environmental and safely requirements, The vehicle should preferably be placed on a grid floor. Most de-waxing agents are AX) inflammable. The de-waxing area should be suitable for the safe use of such products. 1. Remove the preserving agent with a solvent, an emulsifying cleaner or a high-pressure hot water cleaner with added solvent, De-waxing with a high-pressure hot water -~ Cleaner should be done carefully and evenly. Set the high-pressure hot water cleaner to a maximum pressure of 100 bar and a maximum temperature of 90°C. Never direct the jet of wax remover to0 long at the same area, as this could cause serious damage to the paintwork and rubber. If some parts of the treated surface siil have preserving agent on them, treat these areas again in the same way. Note: ‘Asteam cleaner is not suitable for de-waxing because it requires the use of calcium descaling products to keep the inside of the steam coil Clean. The dried residues of these products are dificult to remove. 2. After removing the de-waxing agent, rinse the vehicle thoroughly with water. 12 Rae ©02010 LF45/55 series 2. CLEANING VEHICLES 241 HIGH-PRESSURE CLEANER itis advisable to clean the vehicle with a high-pressure cleaner before starting ‘maintenance or service operations. A clean environment makes the engineer's work easier, and enables any vehicle defects to be noticed at an early stage. Note: Before cleaning the vehicle, check the engine, axles, gearbox, etc. for evidence of leakage. I the vehicle is cleaned with a high-pressure leaner, the latter must be used with care. Itis also important to observe the following points: ~ Make sure that doors, windows and root hatch are securely closed during high-pressure cleaning, = When cleaning the universal joint on the steering box, the spider seals may be forced open by the high-pressure jet of water, 50 that the grease behind them is flushed away, As a result, the spider may ‘get stuck, so that the steering mechanism wil “am” - Ableed screw is fitted to the power steering fluid reservoir ofthe steering gear. Water ‘may enter the tank through this, causing damage to the steering mechanism. ~ When cleaning the radiator/intercooler, be careful not to damage the fins. Do not direct the high-pressure cleaner jet 100 long at the air-conditioning system ‘condenser. As a result of the high temperature, the pressure in the system will become excessive, which may cause damage to the system, ©0201 GENERAL OPERATIONS Cleaning vehicles 24GENERAL OPERATIONS 0 Cleaning vehicles ~ Make sure that no water can enter the differential or the gearbox via the breathers, + Make sure that no water can enter via the reservoir bleed screws of clutch, brakes, trailing axle, etc. The engine and engine compartment can be cleaned with a high-pressure cleaner. ‘Make sure in this case not to spray onto electrical components, such as the starting ‘motor, alternator, etc. Maintain a minimum distance of 50 om between the engine encapsulation and the sprayer nozzle to prevent damage to the encapsulation. Do not direct the jet of water at electrical Connections such as connectors, cable plugs of the vehicle ighting system, etc. Ensure that no water can enter the air intake system via the air intake or its flexible seals. = When the vehicle has been cleaned, it must be lubricated again with a grease gun or via the automatic lubrication system, This is important because it prevents the penetration of moisture and dirt at the various pivot points. 22 LFA5/55 series ©0201 ~0 PAINT TREATMENT 7~ —_LFAS/55 series Contents CONTENTS Page Date 1. PAINT TREATMENT oT 201 1.1. General instructions 4 201 112 _Respraying/pairrepating of cab topcoat and SMC polyester pats 13 0201 1.3 Resprayingipaint repairing chassis finishing 15 0201 1.4 Respraying seed top coats 16 0201 1.5 Respraying thermoplastic polymer parts 17 201 1.6 Respraying glass-fbre reinforced polyester parts 18 201 ©0201 ee 1PAINT TREATMENT 0 Contents: LF45/55 series -_™ ~ ~ 2 par ©02010 PAINT TREATMENT LFA45/55 series Paint treatment 1. PAINT TREATMENT 1.1 GENERAL INSTRUCTIONS In the chapter “Paint treatment”, directives are provided for respraying and repairing DAF paint systems applied on various subsurfaces, ‘The products to be used are supplied by a range of manufacturers. However, only use products {rom well-known manufacturers who can provide all products for the complete paint structure. The Use of these products must be described in the instructions issued by the manufacturer. ‘Work according to the instructions listed below: For rust-emoval, use a rust-removal agent based on phosphoric acid, - Toclean and remove any preserving agents, use an organic, chlorine-free solvent. - _ Use a two-component epoxy-based or polyester-based primer, - Use a two-component epoxy-based or polyester-based filer. = Use a two-component epoxy-based or polyester-based spray filer. - Use a two-component epoxy-based or polyester-based filer. - Use a two-component epoxy PUR finishing coat, with a degree of gloss of more than 92 degrees for cab top coats and a degree of loss of 70 degrees for chassis finishing (measured at 60 degree geometry) Maximum drying temperature is 80°C, with the exception of fibre-glass reinforced polyester parts. Maximum drying temperature of fibre-glass reinforced polyester parts is 60°C. For the paint structure, only use products ‘from the same supplier. Use the products according to the manufacturer's instructions. Never use products containing silicone in an aerosol can. ©0201 1PAINT TREATMENT Paint treatment Failure to follow the generally applicable safety rules for using paints and similar products can result in serious injury and/or danger. During work with a rust-removal agent, wear protective gloves and safety goggles. When using paints and similar products, and when handling paint waste, always work according to the applicable environmental regulations to prevent unnecessary environmental pollution. Colour coding ‘The DAF code number of the cab paint is on the paint identification plate. ‘The paint identification plate is mounted on one of the vehicle's door pillars. ‘The DAF code number for the cab paint is also marked on the vehicle identity cara. The colour code number of the paint ‘manufacturer "Dupont is stated in the code ‘number. The "Dupont" colour code number consists of five or six characters/digits. The "Dupont" colour code number is followed by the paaint colour or an abbreviation, For example, in the code number L1041MEYL, L1041 is the "Dupont" colour code number of the paint, ME indicates that itis a metallic paint and YLis the colour abbreviation, in this case yellow, Removing rust = Apply the rust-removal agent in accordance with the manufacturer's instructions. The ‘concentration of the rust-removal agent must be adapted to the amount of rust. Ideally, use a rust-removal paste on vertical parts. Prevent rust-removal agents entering overiap joints, Leave the rust-removal agent to work for the time specified by the manufacturer. Rinse the area cleaned of rust at least twice with an ample amount of clean tap water. Dry the area cleaned of rust. 12 DAE 0 ‘LFA45/55 series © 0201 ~0 LFAS5/55 series 1.2. RESPRAYING/PAINT REPAIRING OF CAB TOP COAT AND SMC. POLYESTER PARTS Respraying of cab top coat and SMC polyester parts 4. Remove any preserving agents, if applicable; see "General Operations”. 2. Remove any rust with a rust-removal agent. 3. Clean the area to be resprayed with a solvent. 4. Sand the section to be resprayed with 3M Scotch Brite ultrafine or an equivalent product 5, Remove any dust from the sanded section with a Tack-rag cloth, 6. Clean the area to be resprayed with a solvent. 7. Apply primer to any bare patches, 8. Leave the primer to evaporatelary. 9. Apply aller, if necessary. 10. Leave the filer to evaporateltdry. 11, Fine-sand with 8M Scotch Brite utra fine or ‘an equivalent product. 12, Remove any dust from the sanded section with a Tack-rag cloth 18. Clean the area to be resprayed with a solvent. 14. Apply the top coat according to the ‘manufacturers instructions, 15. Leave the top coat to evaporate/ary. Observe the drying time as laid down in the ‘manufacturer's instructions. ©0201 pas PAINT TREATMENT Paint treatment 13PAINT TREATMENT 0 Paint treatment Paint repairing of cab top coat and SMC polyester parts 1. Remove any preserving agents, if applicable; see "General Operations’ 2. Remove any rust with a rust-removal agent. 8. Clean the area to be repaired with a solvent. 4, Sand the area to be repaired first with P80 ‘sand paper and then with P180 sand paper. 5. Remove any dust from the sanded section, with a Tack-rag cloth. 6. Fillthe area to be repaired. 7. Sand the filed area with P180 sand paper. 8 Fine-sand/roughen the area to be sprayed with 3M Scotch Brite ultrafine or an equivalent product. 9. Remove any dust from the sanded section with a Tack-rag cloth. 10. Clean the area to be sprayed with a solvent, 11. Apply a primer. 12. Leave the primer to evaporate/dry. 18. Apply a filler 14, Leave the filer to evaporateldry. 15. If necessary, fine-sand with 3M Scotch Brite ultrafine or an equivalent product. Following fine-sanding, remove any dust. with a Tack-rag cloth and clean the area with a solvent, 16. Apply the top coat according to the manufacturer's instructions, 17. Leave the top coat to evaporate/ary. Observe the drying time as laid down in the manufacturer's instructions, 14 DAE LFA5/55 series ©02010 PAINT TREATMENT LFAS/55 series 1.3 RESPRAYING/PAINT REPAIRING CHASSIS FINISHING 1 "1 ©0201 Remove any preserving agents, if applicable; see “General Operations’ Remove any rust with a rust-removal agent. Clean the area to be treated with solvent. Sand the area to be treated with P80 sand paper Remove any dust from the sanded section with a Tack-rag cloth Clean the area to be treated with solvent. ‘Apply primer to any bare patches. Leave the primer to evaporatery necessary, sand with P180 sand paper. Following sanding, remove any dust with a Tack-rag cloth and clean the area with @ solvent. . Apply the top coat according to the manufacturers instructions. Leave the top coat to evaporate/dry. Observe the drying time as laid down in the manufacturer's instructions. DAE Paint treatment 15PAINT TREATMENT 0 Paint treatment 1.4 RESPRAYING SEED TOP COATS ‘These instructions relate to parts in steel, SMC. (Sheet Moulding Compound) plastic or Glass-fbre reinforced polyester. 1. Remove any preserving agents, if applicable; see "General Operations” 2. Remove any rust with a rust-removal agent. 3. Clean the area to be resprayed with a solvent, 4, Sand the area to be resprayed first with P8O sand paper and then with P180 sand paper. 5, Remove any dust from the sanded section with a Tack-rag cloth. 6. Clean the area to be resprayed with a solvent, 7. Inthe case of plastic, blow ionised air over the area to be resprayed, or clean the area with an anti-static liquid 8, Apply the seed top coat according to the manufacturer's instructions. 9. Leave the paint to evaporate, 10. Observe the drying time as laid down in the manufacturer's instructions. 16 DAE LF45/55 series © 02010 PAINT TREATMENT LF45/55 series Paint treatment 1.5 RESPRAYING THERMOPLASTIC POLYMER PARTS Thermoplastic polymers include the following ‘lastic” plastics: ASA, ABS and PUR. 1. Remove any preserving agents, i applicable; See “General Operations” 2. Clean the area tobe resprayed with a solvent. 3. Sand the area to be resprayed with P180 sand paper 4. Fine-sand with 3M Scotch Brite uta fine or an equivalent product, 5. Remove any dust from the sanded section with a Tack-rag cloth 6. Blow ionised air over the area to be resprayed, or clean the area with an antistatic quid 7. Glean the area to be sprayed with a solvent, 8. Apply an elastic top coat (10-15% elastiier in tho base paint) according to the manufacturer’ instuctons 9. Leave the top coat to evaporateldry. Observe the drying time as laid down inthe manufacturer's instructions ©0201 ee 17PAINT TREATMENT 0 Paint treatment LFAS5/55 series 1.6 RESPRAYING GLASS-FIBRE REINFORCED POLYESTER PARTS. These parts can be recognised by the visible fibre-glass structure on the rear of the part, and the gel coating on the front of the part. 1. Remove any preserving agents, if applicable: see "General Operations’ 2. Clean the area to be resprayed with a solvent. 3. Sand the area to be resprayed first with P&O sand paper and then with P180 sand paper. 4. Remove any dust from the sanded section with a Tack-rag cloth, 5, Fill the area to be resprayed. 6. Leave the filer to dry. 7. Apply spray filler to the part to be resprayed. 8. Leave the spray filler to dry 9. Sand the filed area first with P8O sand paper and then with P180 sand paper. 10. Remove any dust from the area to be. resprayed with a Tack-rag cloth. 11. Clean the area to be resprayed with a solvent. 12, Again remove any dust from the area to be resprayed with a Tack-rag cloth. 18, Blow ionised air over the area to be Tesprayed, or clean the area with an anti-static liquid 14, Apply filler to the area to be resprayed 15. Leave the filler to evaporate/ary. 18 ©0201 ~0 PAINT TREATMENT LF45/55 series 16. If necessary, fine-sand with 3M Scotch Brite ultrafine or an equivalent product. 17. Remove any dust from the area to be resprayed with a Tack-rag clot. 18. Blow ionised air over the area to be resprayed, or clean the area with an anti-static liquid. 19. Apply the top coat according to the manufacturers instructions. 20. Leave the top coat to evaporateldry. Drying ‘temperatures must not exceed 60°C. Comply with the drying times listed in the manufacturers instructions. ©0201 Ba= Paint treatment 19PAINT TREATMENT 0 Paint treatment LFA5/55 series = —™* a ~ ~ 4-10 Bae ©02010 CONVERSION TABLES 7~ __ TFASI55 series Contents CONTENTS Page Date 1. CONVERSION TABLES 4 0201 Consumption ce 0201 Specific consumption " 0201 Speed ce 0201 Temperature " 0201 Weight ce 201 Length 12 201 Area 12 0201 Volume 12 0201 Pressure 13 201 Work 13 0201 Power 43.0200) 0201 ©0201 RAE 1CONVERSION TABLES 0 Contents LFA5/55 series. = ~ 2 war ©0201oO CONVERSION TABLES LFA5/55 series Conversion tables CONSUMPTION ken 1100 Km mmiles/galion (imp) _|__miles/gallon (US) a 100 1x 2.2825 nx 2.382 700 5 282,5 a a nx 0384 7 7K 0425 x 1202 7 SPECIFIC CONSUMPTION g/kW.h gihp.h gibh.n 7 Ib/bh.h 1 0.7355 0.7455 o.on64 136 1 Pr) 0.00224 1.341 0.9863, 1 0.00220 608.45 aar4 4836 1 SPEED emisee maisee ieaih Teotsee valle 7 0.07 0.036 0.03261 0.02237 100 1 38 3.281 2237 27.78 02778 7 oana oat 30.48 0.3048 1.087 1 0.6816 44.70 0.4870 7.609 1.867 1 ‘TEMPERATURE 1 Gals Signs BF = gn Aan B7SISK 1 Fahrenheit = Sip (n - 92) °C = Yip (n - 32)° R= ig (n= 82) + 273. 18K ne Réaumur = S)gn°C= gn + SF = gn + 273.15 K Kelvin =n 278.15 C= % (9273.16) + 32 F= 4g (n- 273.15) A WEIGHT kg [ounces | pounds (ibs) | shorttons* |" longtons* | ton (metr) 1 35.27 2.205 ‘ooore2 |” 00009842 0.001 0.02835 1 0.0625 | 0.008125 | o.o000279 | 0.000285 0.4536 16 7 ‘0.0005 O.000a64 | 0.004596 9072 32000 2000 | 0.8988 0.9072 1016 35640 2240 112 1 1016 1000 aso7s | 2208 7.102 oe [4 “US +UK ©0201 pat oeCONVERSION TABLES 0 Conversion tables LF45/55 series LENGTH mam [inches | feet | _yards = em mile (stat) 7 0.03997 | 0.008267 | doo1084 | 0.007 | 0.000007 | ~o.o000006e14 2a oi 0.08383_| 02777_| 0.0264 | 0.000254 | _0.00007877 3088 2 7 0.5333 | 0.9048 | 0.002048 |” 0.001804 9184 36 3 7 ‘a.9ia4 [0.000974 |” 0.008682 wooo | 0a7_|a2e1 | 1086 | 4 O00 | 0.00062" yoo0000 | a8a70_| 2281 [10936 | i000 1 0214 1609350 63360 5280 1760_| 1609 1.609 1 AREA mm? em? [square inches | square feet | square yards |___m@ 7 001 | 0.00155 0.00001076 | 0.000001196 | 0.000001 rr) 0.155) 0.001076 0.000196 | 0.0001 52 asd ‘o.006sea | 0.000716 | 0.000648 32900 iat i ont 0.09280 336100 7296 2 7 0.8261 77000000 70000) 7550 TO76 196) 1 7] VOLUME om? ‘cubic inches pints quarts gallons* | om (litre) 1 (0.06102 o.0021t4 o.001057 | _0.0002682 0.001 16.39 1 0.03464 o.01732 (01008388 0.01639 4732 28.874664 1 Os 0125 0.4732 946.4 57.75 2 1 0.25 0.5864 3785, 231 8 4 1 3785 7000 61.02 aaa 1.057 0.2642 1 * US Gallon = 0.8327 Imp. Gallons ~ cubic inches | __pints quarts gallons om? (tre) 1 o.0610248 | 0017598 | 0.008790 | o.000219975 0.007 16.387 D 0.02884 0.01487, 0008618 | _0.016367 566.2 | 3467429196 1 Os 01125 (035682 1136.49 69.318 2 1 025 713645 4545.95 277.274 8 + 1 454596 1000 61028 1.7598 0.8799 0219975 1 ** imp. Gallon = 1.201 US Gallons 12 ©02010 CONVERSION TABLES LF45/55 series Conversion tables PRESSURE Pa T bar kgicm? Ibs/sq inch (p.s.i.) atm 7 00007 3.000010 0.000145 0,0000867, 700000 1 10197162 74.500864 0.986883, 38066 5 0.380865 7 14.22 0.9678, 6804.76 ‘0.0609876 | 0.070007 7 0.068046 1010225 01622 7.0888 1470 7 193.82 o.0018982 | 0.0010505, o01898 001818 3306.28 0.089863, 0.03488, 04912 0.9042 9797 82 0.097978 0.09991 1424 0.08868 246.89 0.002889 0.002698 0.09608 0.002456 column of mercury at 15°C Column of water at 15 °C Pa and g = 980.665 cm/sec? and g = 980.665 cm/sec? mm [__inches ™m inches 7 0.0075007 | 0.0002085, o.0007021 0.0040187 700000 750.06708 | 29.590981 10.207359, 401.87015 380665 75.56454 28.96 10.01 0.9678 6894.76 S715 2096 0.7037 0.068045 1018223 760 29.82 10.97 7 199.2 1 0.09867 O.01861 ToT aTs 3386.28 2.40 7 0.3456 0.3942 9797.82 7349 288 1 0.08668 248.09 1.867 0.07048 02540 0.000856 WORK Ni kg | ftlbs. [kwh [pk (metry | Hph weal 7 [rors | OraveeG7 | Teeona0aTT |“o.coocaaarre | 6.OSoocGsTeS | o.DoCeaeaRe amnbss + | 728 | 000002723 | 0vo00087e37 | 0000008652 | _o.0ceae Tssezs0985 | 07086 | 1 | caoo000a7es | o.c0000051206 | d.co000080506 |". co0az28 aeor001.88 | eere0o | zoss00 | __1 7.3588 724i 360 25a7798 | 270000 | 1952800 | 07088 1 29860 wae Beeasr0.a07s | 273760 | 1980000 | 07456 188 7 ei a1a7 3068 _| 27 —|_a0oa | ooorres | ooorser | oonrss 7 POWER we Timer) | mkgieee | kealee HP ibslsee 7 136 102 0.2088 134 7377 07655 1 75 0.1757 0.9865 5425 Boose | 0.01888 7 doceaae | 001815 7.238 4196 5.698 war 1 5015 3088 0.7455 104 76.08 0.1761 o 360 0.007955 | o001e | 0.1083 | o.000se06 | __o.novee 4 ©0201 Bae 13CONVERSION TABLES 0 Conversion tables LFA5/55 series = —™ ~ ~ ~ 1-4 DAE ©0201~ LF45/55 series ©0210 CONTENTS TECHNICAL DATA DIAGNOSTICS INTERNAL CAB COMPONENTS: CAB HEATING EXTERNAL CAB COMPONENTS: CAB SUSPENSION CAB TILTING GEAR SEATS ACCESSORIES1 TECHNICAL DATA LF45/55 series Contents CONTENTS Date 0210 0210 0210 210 0210 o2t0 0210 1. INTERNAL AND EXTERNAL CAB COMPONENTS 4.1 General .. : 112 Tightening torques 2. CAB SUSPENSION ... 21° General .......- 2.2 Tightening torques - 3. CABTILTING GEAR . 3.1 General 0210 3.2. Filing capacities 0210 4, SEATS. 0210 41 General 0210 42. Tightening torques - 5. ACCESSORIES. 5.1 General 5.2 Tightening 0210 0210 0210 210 ©0210TECHNICAL DATA 1 Contents ‘LF45/55 series 2 pae ©02101 ‘LF45/55 series TECHNICAL DATA Internal and external cab components 1. INTERNAL AND EXTERNAL CAB COMPONENTS 1.4 GENERAL Main dimensions and weights ©) Cab dimensions in mm: length (L) width (8) ‘max. height (H) tilting (K) Cab weights: Day cab ‘Sleeper cab Notes: (1) Height (H) dependent on version and tyre size @ Dimension K measured from the front of ‘the bumper. ©0210 Day cab 1600 mm 2130 mm 2900 mm (*) 1105 mm @) 595 kg 750 kg Sleeper Cab 2000 mm 2130 mm 2900 mm () 1105 mm @TECHNICAL DATA 1 internal and external cab components Permissible cab weights: Roof console evenly distributed Roof evenly distributed Weight on the bunk Cab side members ‘Welding on cab side members is NOT Permitted. ‘When repairing the cab side member, you must Use sheet-metal trimming panels, ‘These must be fitted by spot welding, max. 5kg 150kg 125k9 12 poe ‘LF45/55 series ©0210 ~rn 1 TECHNICAL DATA LFAS/S5 series Internal and external cab components Straightening dimensions Door opening dimensions A-D 1283 mm, C.F 887 mm B-E 1591 mm e210 13TECHNICAL DATA 1 Internal and external cab components 14 LFAS5/55 series ©0210 ~TECHNICAL DATA ‘LF45/55 series Cab front dimensions A-B 836 mm c-D 836 mm E-F 836 mm Gel 1973 mm Hed 1973 mm Front panel dimensions Nek 1945 mm K-M 1945 mm ©0210 Internal and external cab components 15TECHNICAL DATA 1 Internal and external cab components: ‘LF45/55 series Field of vision dimensions Mirror size size2 | ses | sea | sizes Pavernent mirror fA} tm tm 125m Wide-angle mirror [8] 25m 15m 125m 25m am Main miror on co-drivers | 30m 35m | 075m am side [C] Main mirror on divers tom 25m side [0] a 16 RBa= ©02101 TECHNICAL DATA LF45/55 series intemal and external cab components Windscreens ‘Curing times for windscreen adhesive Productname | DAF number | Vehicle mobile in | Cab can be titted | Vehicle usable workshop after: after: after: Sikaflex 255 FC 4271129 6 hours: ‘Bhours 12 hours ‘Sika Tack Utrafast | 1241020 2 hours: ‘4 hours 6 hours ‘Sika Tack plus 1957925 1 hour 1 hour © 2 hours: booster Notes: (9 tf vehicle is equipped with an airbag, the ‘curing time is 2 hours A relative humidity of less than 50% delays ‘curing, as does a temperature lower than 20°C. Products applied for bonded windscreens Product name | DAF number | Properties ‘Applications ‘Sikaflex 255 FC 1271129 _ | Processing time “Adhesive (cold process) for 20 min. bonding windscroens ‘Sika Tack UF 1241020 | Processing time "Adhesive (warm process) for 10min. bonding windscreens ‘Sika Tack plus 1957925 | Processing time ‘Adhesive (cold process) for booster 10 min. bonding windscreens ‘Sika Aktivator 1312962 ‘Cleaning fd for cleaning the glass and the frame. ‘Sika remover 1247019 Rlemoval of adhesive which has not SR 208 Yt hardened. Do not use on ‘surfaces to be bonded. ©0210 par 17TECHNICAL DATA 1 Internal and extemal cab components 1.2 TIGHTENING TORQUES ‘The tightening torques stated in this paragraph are different from the standard tightening torques stated in the overview of the standard tightening torques. The other threaded ‘connections which are not stated must therefore be tightened to the tightening torque stated in the overview of standard tightening torques. When attachment bolts and nuts are to be replaced, it is important - unless stated ‘otherwise - that these bolts and nuts are of exactly the same length and property class as ‘the removed ones. Steering wheel ‘Steering wheel attachment bolt Universal joint Universal joint attachment bott Airbag ‘Airbag module attachment bolt Contact unit attachment bott Electronic unit Note: o 18 Al Iways replace the attachment bolt and ut 60 = 5Nm 56 + 5.6 Nm!) 64 1Nm 1.2Nm 10 + 2Nm LF45/55 series ©02101 LF45/55 series 2. CAB SUSPENSION 2.1 GENERAL ‘The day cab can be fitted with rubber spring ‘elements at the front. The version with rubber ‘pring elements at the front does not have a stabiliser. ‘The coil spring elements are fitted with shock absorbers. ‘The length ofthe spring elements and the cab height cannot be adjusted. ‘On models equipped with coil spring elements at the front, a difference in cab height can be corrected to a certain extent using the stabiliser bar. ‘At the rear, coil springs are used. The length of the spring elements varies depending on whether a day cab or a sleeper cab is involved. Cab support, general ‘The distance between the cab ‘supports (A) measured from the left side of the left support to the left side of the right support is: 1000 mm ©0210 Bea TECHNICAL DATA Cab suspension 24TECHNICAL DATA Cab suspension Cab support with silentblock Silent block mounting angle (A) 67° - 71* Cab support with coil spring suspension Silent block mounting angle (A) 18° - 22° 22 1 ‘LF45/55 series ©02101 LFASISS series 2.2. TIGHTENING TORQUES ‘The tightening torques stated inthis paragraph are different from the standard tightening ‘torques stated in the overview of the standard tightening torques. The other threaded ‘connections which are not stated must therefore be tightened to the tightening torque stated in the overview of standard tightening torques. When attachment bolts and nuts are to be replaced, itis important - unless stated ‘otherwise - that these bolts and nuts are of exactly the same length and property class the removed ones. ‘Attachment bolts for cab suspension using coll springs Cab suspension 250 Nm + 150° attachment bolt angular displacement ‘Attachment bolts for cab suspension using rubber spring elements ‘Cab suspension 250 Nm + 150° attachment bolt angular displacement eo210 Bae TECHNICAL DATA Cab suspension 23TECHNICAL DATA 1 Cab suspension LF45/55 series 24 RoE ©0210 ~1 LF4S/55 series 3. CAB TILTING GEAR 3.1 GENERAL ting cylinder Nominal pressure Cab titting pump Nominal pressure Pressure limiting valve 3.2 FILLING CAPACITIES Cab tilting pump Effective oll capacity of the cab-tting pump. ©0210 250 bar 250 bar 350 + 90 bar TECHNICAL DATA Cab tilting gear 34TECHNICAL DATA 1 Cab titing gear LF45/55 series 32 Rar ©0210 ~1 TECHNICAL DATA LF45/55 series Seats 4, SEATS 4.1 GENERAL Height control valve ‘Adjusting dimension X for height control valve 4.2 TIGHTENING TORQUES The tightening torques stated in this paragraph are different from the standard tightening torques stated in the overview of the standard tightening torques. The other threaded ‘connections which are not stated must therefore be tightened to the tightening torque stated in the overview of standard tightening torques. When attachment botts and nuts are to be replaced, itis important - unless stated ‘otherwise - that these bolts and nuts are of ‘exactly the same length and property class as the removed ones. MB attachment bolt M10 attachment bott ‘Attachment bott 7/16" UNF-2B 1-2mm 22.Nm 22Nm 37Nm ©0210 BAe 44TECHNICAL DATA 1 Seats LF45/55 series 42 par ©0210 ~1 TECHNICAL DATA LF45/55 series Accessories 5. ACCESSORIES 5.1 GENERAL Roof spoller ‘Adjusting range of roof spoiler, aerodynamic and adjustable Note: ‘The roof spoiler height can be adjusted using adjusting mechanism (B). ‘The size is the distance measured between the highest roof spoiler edge (P) and the cab roof plate local to the vehicle centreiine. Application compounds for rear alr folls and roof spoilers Productname | DAF number | Properties ‘Applications Sikaflex 252 286578 ie within | Kit for fender and roof spoiler (white) 5 attachment Curing time 2 days. e210 par 54TECHNICAL DATA ‘Accessories 5.2, TIGHTENING TORQUES The tightening torques stated in this paragraph are different from the standard tightening torques stated in the overview of the standard tightening torques. The other threaded Connections which are not stated must therefore be tightened to the tightening torque stated in the overview of standard tightening torques. ‘When attachment bolts and nuts are to be replaced, itis important - unless stated ‘otherwise - that these bolts and nuts are of ‘exactly the same length and property class as the removed ones. Root spolier ‘Attachment nuts Rear air foit Attachment nuts Sun visor Bracket attachment bolts Bolt for attaching the sun visor to the bracket 52 Rae 13Nm 13.Nm 13.Nm 10Nm 1 LF45/55 series ©0210a 1 DIAGNOSTICS LF45/55 series Contents CONTENTS 1. CAB SUSPENSION . 1.1 Faultinding tabie, ©0210DIAGNOSTICS 1 Contents LF45/55 series 2 DAE ©0210 ~1 DIAGNOSTICS LF45/55 series ‘Cab suspension 1. CAB SUSPENSION 1.1. FAULT-FINDING TABLE, CAB TILTING MECHANISM ‘COMPLAINT: TILTING CYLINDER FAILS TO RESPOND Possible cause Remedy ‘Damaged or broken pipe. Fioplace pipe or connection. Pump reservoir empl. “Top up reservoir and check for leakage. ‘Wor or damaged oylinder seal. Replace the cylinder or seal. COMPLAINT: PUMP ROD REBOUNDS Possible cause Remedy ‘Leaking non-return valve. Possible cause ‘Low oil level in oll reservoir. ‘Leaking inlet vaive (bail). Polluted inlet strains ‘COMPLAINT: PUMP ONLY FUNCTIONS IN THE LAST PART OF THE STROKE Disassemble the two-way valve of the pump. ‘Clean and degrease the valve components. place all seals and assemble the two-way valve. Remedy “Top up oll reservoir Remove the two-way valve and check the inlet valve. Clean or replace It. Clean the reservoir and strainer. Possible cause Reservoir level too low. Leaking inlet vaive (ball). ‘Worn or damaged O-rings on the two-way valve. ‘COMPLAINT: PUMP FAILS TO BUILD UP PRESSURE Remedy “Top up the reservoir Remove the two-way valve and check the inlet valve. Clean or replace it. Remove the two-way valve and repiace all seals and O-rings. Pressure-relief valve incorrectly set. ‘Check the pressure relief valve and adjust, if necessary. ©0210 DAF 11DIAGNOSTICS 1 Cab suspension LFA5/55 series ‘COMPLAINT: CAB LOCK GANNOT BE OPENED Possible cause Remedy ‘Damaged or broken pipe. Replace pipe or connection. Jammed piston in locking mechanism. Repair or replace the locking mechanism, ‘COMPLAINT: CAB CANNOT BE TILTED Poselble cause Remedy ‘Jammed piston in cab locking mechanism. Repair or replace the locking mechanism. ‘Pump fails to build up pressure. ‘Check the operation of the pump. 12 pee e2101 INTERNAL CAB COMPONENTS. LF45/55 series Contents CONTENTS Page Date - 0210 1. SAFETY INSTRUCTIONS... tt. 2 GENERAL . 2A... 0210 2.1 Overview drawing, interior cab components BAL. ato 22 System description, steering column. 22.0.1! oat 3. INSPECTION AND ADJUSTMENT 3.1. Inspection, steering column setting valve . 4, REMOVAL AND INSTALLATION . 4.1" Removal and installation, switches 4.2 Removal and installation, dashboard panels 13 Removal and installation of complete dashboard . Femaval and instalation, pneumatic switchvale of steering column adjustment unit . 4.8 Removal and installation, steering column - 4.8 Removal and installation, steering wheel 4,7 Removal and installation, door panel. 4.8 Removal and installation, manually operated window mechanism .- 49 Removal and instalation, electrically operated window mechanism 0210 0210 0210 0210 0210 0210 0210 0210 0210 210 410 Removal and installation, roof console . . + 0210 Removal and installation, interior lighting - 0210 : £0210 210 210 0210 0210 0210 0210 Removal and installation, door lock cylinder Removal and installation, engine brake switch . Removal and installation, rear wall lining Removal and installation, roof ining. Flemoval and installation, side wall ining’. Removal and installation, storage trays (sieeper cab) . ©0210INTERNAL CAB COMPONENTS: 1 Contents LF45/55 series ©02101 INTERNAL CAB COMPONENTS LF45/55 series Safety instructions 1. SAFETY INSTRUCTIONS General The cab is equipped with a hydraulic titing mechanism. The pump is located on co-driver's side at the rear of the cab. The cab locks are ‘pened hydraulically during pumping. Before titing the cab, make sure that the doors are closed, that there are no loose items in the ‘cab and that the gear lever is in neutral. Tit the cab fully forward if work must be carried out undemeath the cab. ‘You can stop the cab tilting forward. A) Sesviinedy tring te tp toe reverse tilting position. When working on a tilted cab (for ‘example when welding, ‘spray-painting or applying bitumen coatings), be sure to cover the piston rod of the lifting cylinder. ‘Welding spatter and paint on th piston rod will Inevitably cause ‘damage to the oll seal. Inspection after a collision Before titing the cab after a colision, check the cab rests, the cab hinges and the attachment of ‘the ling cylinder to the chassis member and cab for cracks. It the vehicle has been Involved in a collision, the cab must under no circumstances be tilted without due precautions. The end stop in the Iiting cylinder may be damaged, which might cause the cab to shoot past its end stop. If possible, suspend the cab in slings and put a stand in front of the cab. Make sure that there is. ‘no one in front of the cab while its being tted. ©0210 1INTERNAL CAB COMPONENTS 1 Safety instructions Replacing the lifting cylinder ‘After a colsion, always check the lifting cylinder for internal damage. Replace the lifting cylinder if damaged or if you are in doubt as to the its condition. ‘Always replace the cylinder if one of the folowing pons has occurred during a colision: the cab has been pulled out of the cab locks, B. the cab locks have been deformed or damaged, . the rear cab springs have been deformed ‘or damaged. Airbag and seat belt tensioner safety Instructions ‘Never disconnect an electrical connection in the airbag or seat belt tensioner circuits with the ignition switched on. + Allwork on pyrotechnic systems (systems with airbag(s) andlor seat belt tensioner(s)) ‘may only be carried out by employees of approved DAF dealers or workshops who are sufficiently trained on these systems. = The use of pyrotechnic systems (systems with aitbag(s) andlor seat belt tensioner(s)) is subject to various national laws, The legal stipulations must be observed. 12 par LFA5/S5 series ©02101 INTERNAL CAB COMPONENTS ~~ LF4S/55 series Safety instructions + Vehicles equipped with a pyrotechnic system (system with airbag(s) and/or seat belt tensioner(s)) can be identified by a sticker with an airbag symbol on the windscreen and/or with the word AIRBAG. ‘on the airbag unt on the steering wheel. = Ifthe vehicle is equipped with an airbag and seat bet tensioner system while there is no airbag symbol on the windscreen, this symbol will have to be applied as yet lam wa = Its not permitted to install accessories on airbag and seat belt tensioner parts or in their operating zones afterwards. The ‘operating zone covers an area the size of a ball with a diameter of 80 om. Only accessories approved by DAF for vehicles with an airbag andlor seat belt tensioner ‘may be installed, in the place indicated by DAF and in the manner outined by DAF. = Using equipment or objects that generate strong electromagnetic fields in the vicinity of parts ofthe airbag/seat belt tensioner system can lead to unwanted activation of the aitbag and/or seat belt tensioner or can ‘make proper operation of the system impossible. The use of such equipment or ‘objects in the vicinity of parts of the airbag/seat bett tensioner system is therefore not recommended. ©0210 par 13INTERNAL CAB COMPONENTS Safety instructions 14 tts not allowed to leave pyrotechnic units {airbags and/or seat betttensioners) Unattended. If repairs toa vehicle continue for a long time and pyrotechnic units (airbags and/or seat belt tensioners) are Involved in the repair, the pyrotechnic units must be stored safely (under lock and key). This means that the storage location must meet local requirements relating to pyrotechnic materials. The pyrotechnic Units may not be stored together with different hazardous substances and the location must have the relevant hazard warning symbols and fire protection facilities. Before any work is carried out on a pyrotechnic part (airbag and/or seat belt tensioner): a. switch off the ignition, the negative battery terminal clamp ‘must be separated carefully. wait at least 5 minutes. It pyrotechnic units have been activated in a ‘crash, the electronic unit and the contact Unit must be replaced in addition to the pyrotechnic units. The cable harness ‘assembly and connectors must be inspected visually. if damage or overload is established, the cable hamess assembly ‘must be replaced. 1 LFA5/55 series ©02101 INTERNAL CAB COMPONENTS LF45/55 series 2. GENERAL 2.1 OVERVIEW DRAWING, INTERIOR CAB COMPONENTS ‘Lef-side ventilation grille Instrument panel Gamish moulding Radio pane! Frame rim cover| Upper dashboard panel on driver's side Central console control panel Upper side of cover panel Upper side of cover 1. Right-side ventilation grile |. Right-side dashboard panel Ld on central box Lower dashboard panel on co-criver’s side . Ashtray 5. Engine tunnel dashboard panel 3. Lower dashboard panel on driver's side ” Steering column dashboard panel Nogaenae ©0210 General 24INTERNAL CAB COMPONENTS. 1 General LF45/55 series 2.2 SYSTEM DESCRIPTION, STEERING COLUMN ‘The titing angle of the steering column can be adjusted manually or pneumatically. ‘A spring-loaded clamping mechanism fixes the ‘steering column in position. ‘The pneumatically adjusted steering column is unlocked using the air cylinder behind the steering column, ‘The operating valve (switch) is situated behind the driver's seat. This valve can be operated by the heel 22 RAE ©0210 ~1 INTERNAL CAB COMPONENTS TF45/55 series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1. INSPECTION, STEERING COLUMN SETTING VALVE 1. Check whether the angle of the steering ‘column can be adjusted, once the switch is pressed in with the heel. 2. Check that the adjustment mechanism is securely locked again when the switch is released. 3. If this is not the case, check that no air pipe is trapped. If nat, replace the valve (switch). ©0210INTERNAL CAB COMPONENTS 1 Inspection and adjustment LF45/55 series ©0210 ~1 INTERNAL CAB COMPONENTS LF45/55 series Removal and installation 4, REMOVAL AND INSTALLATION 4.1 REMOVAL AND INSTALLATION, SWITCHES Removing switches Insert a feeler gauge of approx. 1 mm straight between the switch and the panel at the side of the finger-sized depression (A), until it touches the inside of the panel. 2. Remove the switch from its locked position ‘by carefully moving the feeler gauge in the ditection of the arrow (B).. 3. Carefully remove the switch from the panel. In doing s0, ensure that the connector lock does not catch behind the panel, causing the connector to fall behind the panel. 4. Ifnecessary, remove the switch from the ‘connector. Installing switches 1, Fitthe connector. 2. Insert the switch into the opening in the panel and press until you can feel itock. 0 > ul) ©0210 atINTERNAL CAB COMPONENTS 1 Removal and installation LFA5/65 series 4.2 REMOVAL AND INSTALLATION, DASHBOARD PANELS Not Dashboard panel removal and installation is listed in the correct sequence. To allow each following panel to be removed, the earlier specified panels must be removed frst. Removing steering column dashboard panel 1. necessary, remove the floor mat. 2. Using the steering column setting, move the steering wheel tos highest possible position. 3. Remove the attachment botts (1) and panel plug (2) and subsequently the steering column dashboard panel Removing the lower dashboard panel on co-driver's side 1. Remove the attachment bolts from the ower dashboard panel on co-driver's side Remove the lower dashboard panel on co-driver’s side Removing the engine tunnel dashboard panel 1. Remove the attachment bolts (1) and the panel plugs (2). Remove the engine tunnel ‘cover panel. 2. Loosen the 12V power supply connector at the rear. 4-2 Par ©02101 INTERNAL CAB COMPONENTS. LF45/55 series Removing the instrument pane! Remove the attachment bolts (1) of the ‘gamish moulding (2) around the instrument panel (3). 2. Carefully pull the mounting clips (see arrows) holding down the gamish moulding (2) from the dashboard panel. 3. Remove the attachment bolts from the instrument panel (3). 4, Remove the instrument panel (2). 5. Remove the connector from the instrument panel (3). Removing the lower dashboard panel on driver's side 1, Remove the attachment bolts (1). Remove the dashboard panel. 2. Loosen the headlamp height adjustment ‘connector at the rear. 3. Remove the attachment bolts from the ‘connector block at the rear of the dashboard panel. 4. Remove the connector block. Removing the window frame cover panel Remove the attachment botts (1) from the window frame. 2. Take the cover panel out of the window frame. e210 Removal and installationINTERNAL CAB COMPONENTS Removal and installation Removing the upper, cover Remove the attachment bolts at the bottom of the cover. Remove the cover from the upper cover panel by titing t upwards. Removing the central console contol panel Remove the switches (9) from the control panel in the central console (6). Remove the ashtray (2) rom the control panel in the central console (5). Remove the attachment bolts (1) fm control panel in the central console (6). Remove the control panel from the central console (5) Disconnect the connector ofthe cigarette lighter (4). Removing the right-side dashboard panel 1 2, 44 Remove the dashboard panel attachment bolts. Remove the connector from the stepwell lighting door switch 1 ‘LF45/55 series Ba= ©02101 LFAS/S55 series Removing the upper dashboard panel on driver's side 1. Remove the attachment bolts (1) from the radio pane! (2). 2. Remove the attachment botts (3) from the dashboard panel. 3. Cut the cable binders that are used to attach the wiring hamesses to the dashboard panel. 4, Remove the dashboard panel. Unhook the radio panel (2) from the dashboard panel. Disconnect the connector of the light switch (4) and the stepwell lighting door switch. Installing the upper dashboard panel on driver's side 1. Fitthe connector ofthe light switch (4) and the stepwell lighting door switch. 2. Fitthe dashboard panel. Hook the radio panel (2) to the dashboard panel. 3. Fix the removed cable harnesses to the dashboard panel using cable binders. 4, Fitthe dashboard panel attachment bolts (3). 5. Fit the attachment bots (1) of the radio panel (2) to the dashboard panel. Installing the right-side dashboard panel 1. Fitthe connector ofthe stepwell lighting door switch to the right-side dashboard. INTERNAL CAB COMPONENTS Removal and installation ES aaa 2. Fitthe right-side dashboard panel using the = 4 ea os ©0210 RBar 45INTERNAL CAB COMPONENTS Removal and installation Installing the central console control panel 1. Reefitthe connector of the cigarette lighter (4) to the rear of the control panel of the central console (5). 2. Fitthe control panel of the central console (6) to the dashboard. 3. Hook up the switches (3) from the control ppanel in the central console (5) to the connectors. Re-ft the switches (2) to the control panel in the central console (5). 4. Secure the control panel in the central ‘console (5) using the attachment bolts (1). 5. Fitthe ashtray (2) into the control panel in the central console (6). Fitting the upper cover 1. Hook the cover into the cover panel. Fitthe ‘cover into the cover panel using the attachment bolts, Fitting the cover panel into the window frame 41. Fitthe cover panel into the window frame using the attachment bolts (1). 46 1 ‘LF45/55 series 1 kone ©02101 LFAS/S5 series Fitng the lower dashboard panel on driver's al 1. Fitthe connector block to the rear of the aahboard pret using the attachment 2. Fitthe connector ofthe headlamp height ‘adjustment unt to the dashboard panel. 8. Fitthe dashboard panel using the ‘attachment bolts (1) Instaing the instrument pane Fit the connector of the instrument panel (3). 2. Fitthe instrument panel (3) to the dashboard panel using the atiachment 3. Push the garish moulding (2) back onto the dashboard panel using the mounting clips. Fix the garnish moulding (2) onto the gesthoard pane using the atachment iting the engine tunnel dashboard panel Flemove the attachment bots (1) and the Panel plugs (2). Remove the engine tunnel ‘cover panel. 2. Fitthe connector of the 12V power supply 10 the rear of the engine tunnel dashboard panel. ©0210 INTERNAL CAB COMPONENTS Removal and installation Bae a7INTERNAL CAB COMPONENTS 1 Removal and installation LFA4S/S5 series Fitting the lower dashboard panel on co-driver's side 1. Fit the lower dashboard panel on co-driver's using the attachment bolts. Installing the steering column dashboard nel 4. Fitthe steering column dashboard panel Using the attachment bolts (1) and panel plug (2). ©02101 LF45/55 series INTERNAL CAB COMPONENTS Removal and installation 4.3 REMOVAL AND INSTALLATION OF COMPLETE DASHBOARD Removing the deshivoerd Disconnect the earth lead from the battery terminal. 2. Remove the attachment bolts and the panel plug (6). Remove the steering column cover panel. 3. Remove the attachment bolts (1), (2) and {@) and remove the cover panel on co-driver’s side. 4, Remove the attachment bolts (4) and the panel plugs (5). Remove the engine tunnel ‘cover panel. Remove the connector from the 12V power supply. 5. Remove the attachment bolts (7) and remove the upper cover panel. 6. Open the grille. ©0210INTERNAL CAB COMPONENTS 1 Removal and installation 7. Remove the attachment bott (1). 8, Remove the protective cover by pressing the retainer 2) aside. 98. Detach the connector (1) from the connecting bloc 10. Press the connecting block retainer (2) inside and push the complete connecting block inside. 11. Remove the cover plate (2) by releasing the retainer (1). 4-10 Bae ‘LF45/55 series ©0210 ~~ 1 INTERNAL CAB COMPONENTS LF45/55 series Removal and installation 12, Flemove the connectors (2). 19, Push the retainers (1) aside and the ‘connector holder plate inside. 114, Remove the attachment botts (1) from the fiter casing and remove the fier casing (2). 15. lemove the attachment bots (1). 16. Remove the heater hoses (2) and seal the heater tubes. 17. Remove the connectors to the left and right Of the steering column, ©0210 Bae attINTERNAL CAB COMPONENTS 1 Removal and installation LF45/55 series 18. Remove the connectors (2) and the earth connections (3). 19. Remove the attachment bolts on the underside of the dashboard, left and right. 20. Remove the attachment bolts (4) and (1). 21, Pull the cover plate in the A-pillar out of the retainer, remove the grip attachment bolt and remove the grip (5). 22, Remove the floor mats. Remove the diagnostic and ECAS connectors by taking the wiring apart and then removing the attachment bolts. Remove the connectors from the bracket. 23, Remove the floor plate above the wiring Ks 00906 24, Remove the seat wiring 25. Remove the attachment bolts from the window frame. 26. Remove the attachment botts on the underside and remove the complete dashboard. Fitting the dashboard 1. Fitthe dashboard and secure it in the window frame using a few attachment bots. 2. Fitthe seat wiring 8. Install the floor plate above the wiring 4. Fitthe ECAS and diagnostic connectors to the bracket. 5. Fitthe grip and the cover panet in the Acpilar 6. Fitthe connectors in the central box. 7. Remove the seals from the coolant hoses and attach the hoses. 8. Fitthe connectors to the left and right of the steering column. 412 ©0210~ ~~ 1 INTERNAL CAB COMPONENTS LFAS/S5 series Removal and installation 9. Insert the attachment bolts (1). 10. Fit the heater hoses (2). 11. Fitthe fiter casing (2). Secure the fiter ‘casing using the attachment bolts (1). 12, Fitthe plate for the connectors via the Inside and press it into the retainers (2) 18, Fitthe connectors (1). 14, Fitthe cover plate. ©0210 eae 413INTERNAL CAB COMPONENTS 1 Removal and installation ‘LFA5/55 series 16. Fit the connecting block via the inside and press it fimly into the retainers (2). 16. Fitthe connectors (1) to the connecting block. Pay attention to the markings on the ‘components. 17. Fit the protective cover to the cab lead through and secure it using the attachment bolt (1). 18. Close the grille. 19, Fitthe attachment bolts under the dashboard to the left and right. 20. Secure the attachment bolts in the window frame. 21. Fitthe dashboard panels on co-driver's side, 22. Fitthe steering column dashboard panels. 23. Fitthe connector of the 12V power supply to the engine tunnel cover panel. 24. Fitthe cover panel to the engine tunnel. 25. Fitthe earth lead to the battery terminal. 414 RBar ©0210 ~1 INTERNAL CAB COMPONENTS LF 45/55 series Removal and installation 4.4 REMOVAL AND INSTALLATION, PNEUMATIC SWITCH/VALVE OF ‘STEERING COLUMN ADJUSTMENT UNIT Removing the preumatio sntch/valve ofthe steering column adjustment 1. Lay the floor mat aside. 2. Remove the attachment bolts (1) from the 8. Remove the bracket holding the >. Disconnect the air pipes (2) and remove the switchivalve. ©0210INTERNAL CAB COMPONENTS 1 Removal and installation Fitting the pneumatic switchivaive 1. Fitthe air pipes (2) tothe switch/valve. 2. Fitthe switchivalve and secure them using the attachment botts (1). 3. Check the operation of the switch/valve, see chapter "Inspection and Adjustment”. 4, Reposition the floor mat. 4-16 LF45/55 series = ©02101 LF45/55 series 4.5 REMOVAL AND INSTALLATION, STEERING COLUMN Note: steering wheel with an airbag can be recognised by the inscription “airbag” on the ‘cover plate and the "Airbag" sticker on the windscreen. Steering wheel model without airbag Removing the steering column without airbag steering wheel 1. Place the steering box in the central position using the marks. 2. Remove the steering column panel. 3. Depending on the work to be carried out, ‘remove the floor dust cover or the cover panels beneath the steering wheel. 4, It applicable, remove the steering column adjustment air pipe. 5. Remove the connectors from the steering column. 6. Remove the attachment bolt of one tuniversal joint of the steering shaft (depending on the operations to be performed; either the universal joint beneath the steering wheel or the universal joint on the steering box). Before loosening, mark the position of the universal joint versus the steering shaft. 7. Remove the attachment bolts. One of the attachment bolts is a security bolt. Remove this using a drift. 8. Remove the steering column, ©0210 eae INTERNAL CAB COMPONENTS Removal and installation 417INTERNAL CAB COMPONENTS 1 Removal and installation LFA45/55 series Installing the steering column without airbag steering wheel 1. Check whether the steering box is sill in the Central position, using the markings. 2. Fitthe steering column to the steering shat ‘and make sure that the marks between the universal joint and steering shatt align. Fit a new attachment bot with nut inthe universal joint. Tighten the attachment bott to the specitied torque, see main group “Technical data’ 3. Place the steering column by tightening the top attachment bolts by hand. 4. Attach the air pipes to the connection block behind the dashboard. Check to see that the air pipes are not in contact with any ‘moving parts. 5. Fitthe steering column connectors. 6. Fitthe lower attachment bolts and lock the steering column. 7. Fitthe steering column panel and secure it with the attachment bolts and panel clips. 418 Ro= ©02101 INTERNAL CAB COMPONENTS LF45/55 series _- Observe the warnings and safety A instructions applicable to working Gnan eloey stem. Removing the stering column with bag Steering whee! 1. Remove the airbag module. 2. Place the steering box in the central position using the marks. Remove the panel under the tachograph. There must at least be 5 minutes waiting time between disconnecting the battery leads and loosening the alrbag connector. Non-abservance ‘of the 5 minutes waltin time may result in the alrbag being activated ‘when the connector is removed. 4, Remove the steering column panel. 5. Depending on the work to be carried out, remove the floor dust cover or the cover panels under the steering wheel. 6. applicable, remove the steering column adjustment air pipe. 7. Remove the connectors from the steering column. ©0210 F Removal and installation 419INTERNAL CAB COMPONENTS Removal and installation ‘8. Remove the attachment bolt of one universal joint of the steering shaft (depending on the operations to be Performed; either the universal joint under the steering wheel or the universal joint on the steering box). Before loosening, mark the position of the universal joint versus the steering shaft. 9. Lock the steering wheel to prevent it from turning, using, for example, adhesive tape It the steering wheel is rotated more than 3 turns to the left or right from the centre position, the airbag contact unit will get damaged. 10. Remove the attachment bolts. One of the attachment bolts is a security boll. Remove this using a dei. 11. Remove the steering column. 1 LFA5/55 series ©0210 ~1 LF45/65 series Installing the steering column with airbag steering wheel 1. Check that the steering box is stil in the central position, using the marks. 2. Fitthe steering column to the steering shaft ‘and make sure that the marks between the universal oint and steering shaft align. Fit new attachment bolt with nut in the universal joint. ‘Tighten the attachment bolt to the specified torque, see main group "Technical data’. 3. Place the stering column by Ughtening the top attachment bolts by hand. 4. Attach the air pipes to the connection block. behind the dashboard. Check to see that the air pipes are not in contact with any ‘moving parts. Fit the steering column connectors. Fitthe lower attachment bolts and lock the steering column. 7. Fitthe steering column panel and secure it ‘with the attachment bolts and panel clips. Fitthe panel. Fit the airbag module. ©0210 INTERNAL CAB COMPONENTS Removal and installationINTERNAL CAB COMPONENTS 1 Removal and installation LF45/55 series = 4.6 REMOVAL AND INSTALLATION, STEERING WHEEL Note: steering wheel with an airbag can be recognised by the inscription “Airbag” on the cover plate and the “Airbag” sticker on the windscreen. Steering wheel without airbag Flemoving the steering wheel without airbag 1. Check that the steering wheel is not equipped with an airbag. 2, Place the steering box in the central position using the marks. ~ 8. Remove the cover plate from the steering wheel. 4. Remove the steering whee! bolt (2). 5. Make marks (A and B) on the steering wheel (1) and the steering shaft (3). ~ ~ 4-22 Rae ©02101 INTERNAL CAB COMPONENTS ‘LF45/55 series Removal and installation 6. Fit the steering wheel puller {DAF no. 1451995) on the steering wheel. 7. Make sure the bottom of the spindle (1) is level with the bottom of the attachment bolts (2). 8. Tum the spindle (1) approximately 10 mm into the steering shat. 9, Turn both attachment botts (2) approximately 10 mm into the steering wheel. 10. Evenly tighten both attachment botts (2) ateratoly unl the steering wheel comes loose. Fitting the steering wheel without airbag 41. Fitthe steering wheel (1) on the steering shaft (8) 80 thatthe markings on the steering wheel and steering shaft (A and B) “align’. Ensure that the ridges on the rear of the steering wheel fall into the recesses. ‘Check that the steering box is stilin the Central position, fa new steering whee is fitted. 2. Fitthe attachment bott (2). Tighten the attachment bot to the specified torque, see ‘main group “Technical data’. 3. Fitthe cover plate on the steering wheel. ©0210 BaE 4.23INTERNAL CAB COMPONENTS 1 Removal and installation ‘LFAS/S5 series Steering whee! with airbag > states Son Removing the steering wheel with airbag 1. Disconnect the earth leads from the battery. 2. Place the steering box in the central position using the marks. 3. Remove the covers from the steering column There musta lesst be 5 minutes AB) ‘ating between siecomectng 1¢ battery leads and loosening the airbag connector. Non-observance Ot tho's minutes wltg tio may result in the airbag being activated wwhen the connotea removed 4. Remove the steering wheel bolt (2) 5. Make marks (A and B) on the steering whee! (1) and the steering shatt (3). ©02101 INTERNAL CAB COMPONENTS LF45/55 series 6. Fitthe steering whee! puller (DAF no, 1451995) on the steering wheel. 7. Make sure the bottom of the spindle (1) is level with the bottom of the attachment bolts (2). 8. Tum the spindle (1) approximately 10 mm Into the steering shaft. 9. Tum both attachment bolts (2) approximately 10 mm into the steering 10. Evenly tighten both attachment bots (2) alternately until the steering wheel comes loose. Fitting the steering wheel with alrbag 4. Fitthe steering whee! (1) onthe steering shaft (3) 60 that the markings on the steering wheel and steering shatt (A and B) “align. Ensure that the ridges on the rear of the steering wheel fall into the recesses. Check that the steering box is stil in the Central positon, ita new steering whee! is fitted. 2. Fitthe attachment bot (2). Tighten the attachment bolt tothe specified torque, see ‘main group “Technical data’. 3. Fitthe airbag module. 4, Fitthe steering column covers. ©0210 Removal and installation Bar 4-25INTERNAL CAB COMPONENTS 1 Removal and installation ‘LFA5/S55 series 4.7 REMOVAL AND INSTALLATION, DOOR PANEL, Removing the door pane Loosen the cap from the grip by pushing a screwdriver info the recesses (1). 2. Remove the cap from the grip. Remove the caps (2) at the bottom of the door. 4, Remove the attachment bolts from the door. 5. Remove the attachment bolts (1) from the rip. 6. Disconnect the electric window and mirror connectors at the inside of the grip. 7. Push the grip down as far as it will go. 8. Push the control cable clip (2) out of the rip. 9. Remove the control cable from the door knob. Put the grip aside. 10. Pull the door panel out of the mounting clips in the door, starting at the bottom. 11. Lift the door panel out of the window frame. 4-26 ©02101 INTERNAL CAB COMPONENTS. ‘LF45/55 series Removal and installation Installing the door panel 1. Fitthe door pane into the upper part of the ‘window frame. 2. Press the door panel all around into the door using the mounting clips. 3. Secure the lower part ofthe door panel Using the attachment botts and ft the caps. ‘4. Position the grip on the door panel. 5. Fitthe nipple of the control cable in the door Gatch ote ap (A). Ft the coupe nto the rip (8). 6. Secure the control cable coupler into the stip (C) using the mounting clip. 7. Fitthe automatic mirror and window ‘connectors into the grip. 8. Foc the gtip to the door using the attachment bolts (1). 9. Fitthe grip cap. e210 Bae 427INTERNAL CAB COMPONENTS 1 Removal and installation LFAS5/55 series 4.8 REMOVAL AND INSTALLATION, MANUALLY OPERATED WINDOW MECHANISM Removing the manually operated window mechanism 1. Remove the door panel 2. Remove the door screen. ‘3. Support the door window using a block (1) ‘and remove the attachment bolts (4). Femove the window on the underside so that itis no longer locked in position. 4, Remove the attachment bolts (3) and the attachment nut (2) from the window mechanism, 5. Tilt the window mechanism (5) and remove it through the bottom of the door. Installing manually operated window mechanism 1. Fitthe window mechanism (5) through the bottom of the door. 2. Remove the block (1) and hook up the door ‘window in the window mechanism. Secure the door window with the attachment bolts (4). 8. Secure the window mechanism with the attachment bolts (3) and nut. 4. Close the door window until nearly shut. Check that the top edge of the window is parallel with the window frame. Loosen the attachment bolts (4), if necessary. Move the window to the correct position and re-tighten the attachment bolts. 6. Fitthe door screen, 6. Install the door panel ©02101 INTERNAL CAB COMPONENTS LF45/55 series Removal and installation 4.9 REMOVAL AND INSTALLATION, ELECTRICALLY OPERATED WINDOW MECHANISM Removing the electrically operated window mechanism 1. Remove the door panel. 2. Remove the door screen. 3. Lower the window, remove the attachment bolts (2) and slide the window up. Support the window with a block (1). 4. Disconnect the connector (4) from the electric motor. 5. Remove the attachment bolts (2) and nuts {@) and remove the window mechanism ‘rom the door through the opening. Installing the electrically operated window mechanism 1. Fitthe window mechanism in the door and fit the attachment bolts (2) and attachment ruts (3). 2. Connect the electric motor connector (4). 3. Lower the window and attach the window ‘mechanism to the door using the attachment botts (2). 4. Operate the window switch. Close the window until nearly shut. ‘Check that the top edge of the window is parallel wth the window frame. Loosen the attachment botts (2), if necessary. Move the window to the correct position and re-tighten the attachment bolts. 5. Fit the door screen. 6. Install the door panel. ki ogre RAE 429 e210INTERNAL CAB COMPONENTS: 1 Removal and installation ‘LF45/55 series 4.10 REMOVAL AND INSTALLATION, ROOF CONSOLE Removing the root console Remove the top lighting attachment bolts ‘rom the outside of the vehicle and put the lighting aside. 2. Remove the top lighting connector. 3. Remove the wiring covers in the roof console. 4, Remove the interior lighting connector. 5. Remove the loudspeaker and its connector. 6. Remove the wiring hamess from the root console, 7. Remove the attachment bolts (2) from the ‘oof console in the window frame. 8. Remove the covers (1) at the front and. remove the attachments bolts behind these covers. 9, Remove the roof console. Instaing the root console ut the roof console in place and position it using a few attachment bolts. 2. Place the attachment bolts atthe front of the roof console and tighten them, 8. Fitthe connectors forthe interior lighting, loudspeaker and top lighting 4. Fitthe attachment botts (2) in the window frame, 5. Secure the top lighting withthe attachment bolts. 6. Fitthe covers (1) ©02101 INTERNAL CAB COMPONENTS LF45/55 series Removal and installation 4.11 REMOVAL AND INSTALLATION, INTERIOR LIGHTING Removing the interior celling lighting 1. Puta screwdriver between the glass cover (1) and the holder (2). 2. Remove the glass cover (1). 3. Bend the lock levers (B) inwards. 4. Unplug the connectors and remove the lamp holder. Fitting the interlor celling lighting 4. Bend the lock levers (B) outwards. 2. Hook up the connectors and fit the lamp holder (2). 3. Fitthe glass cover (1). 4.12 REMOVAL AND INSTALLATION, IGNITION LOCK Removing the ignition lock 1. Remove the covers around the steering column under the steering wheel. 2. Disconnect the connectors (behind the dashboard). 3. Diill off the head of the security bolt, use a bit with the same diameter as the hole ‘where the head falls and remove the ignition lock. Installing the Ignition lock 41. Install the ignition lock. 2, Tighten the security bolts with such a tightening torque that the heads break off, nore 3. Fit the covers around the steering column. ©0210 poe 431INTERNAL CAB COMPONENTS 1 Removal and installation LF45/55 series 4.13 REMOVAL AND INSTALLATION, COMPLETE DOOR LOCK MECHANISM Removing the complete door lock anism 1. Close the window. 2. Remove the door panel. 3. Gently remove the plastic sereen (1) from the door. 4. Remove the attachment bolts (6) from the closing mechanism. 5. Remove the attachment bolts (6) from the door lock mechanism. 6. Remove the plug (4) from the central door locking mechanism. 7. Remove the clamping strips (3) holding in place the main wiring harness (2) and the Wiring harness of the central door locking mechanism. 8. Lay the main wiring harness (2) aside 9. Remove the control rod by loosening the ‘control rod locking (1) through titing and tunhooking the control rod from the locking. 10. Unhook the door lock mechanism from the {door and allow it to be lowered together with the door locking 11. Remove the attachment bolts (3) from the door lock mechanism. 4-32 par ©0210 “A1 INTERNAL CAB COMPONENTS ‘LF45/55 series Removal and installation 12, Remove the complete door lock mechanism ‘rom the outside. 18. Remove the closing mechanism together with the motor of the central door locking from the inside of the door. Fitting the complete door lock mechanism 1. Fitthe closing mechanism in the door. 2. Hook the control cable (3) in the door lock mechanism. ‘3. Position the door lack mechanism in the door. ‘4. Hook the control rod in the locking (1) of the ‘operating lever. Lock the control rod by licking the locking (1) in place over the ccontrol rod. 5. Fitthe attachment botts (6) of the closing ‘mechanism. 6. Fitthe attachment bolts (5) of the door lock ‘mechanism. 6 7. Fitthe plug (4). 8 Secure the main wiring hamess (2), the wiring hamness of the central door locking and the plug (4) to the threaded ends at the inside of the door, using clamping strips. 9, Fitthe door screen (1). 10. Install the door panel. ©0210 eer 4-33INTERNAL CAB COMPONENTS 1 Removal and installation ‘LFAS/S5 series 4.14 REMOVAL AND INSTALLATION, DOOR LOCK CYLINDER Removing the door lock cylinder 1. Remove the complete door lock ‘mechanism. 2. Remove the circlip (2). 3. Detach the operating lever (4). 4. Loosen the locking spring (1) and remove the door lock cylinder (2) Fitting the door tock eylinder 1. Fit the door lock cylinder (2). Fit the locking spring (1). 2. Fitthe operating lever (4 3. Fitthe locking rng (3). 4. Fitthe complete door lock mechanism. 4.15 REMOVAL AND INSTALLATION, ENGINE BRAKE SWITCH Removing the engine brake switch 1. Remove the covers from the steering column. 2. Remove the engine brake switch connector ‘rom the connector holder next to the steering column. 3. Remove the attachment bolts (1) from the 2 tengine brake switch, 4. Remove the engine brake switch (2). Installing the engine brake switch 1. Fitthe engine brake switch (2). 2. Secure the attachment bots (1). 3. Fitthe connector. 4, Fit the steering column covers. ©0210 ~1 INTERNAL CAB COMPONENTS LF45/55 series 4.16 REMOVAL AND INSTALLATION, REAR WALL LINING Removing the rear wall lining Note: When working on the upholstery make sure hands are clean or wear gloves. Remove the panel clips on the rear wall of the cab. 2. ttapplicable, remove the thermostat and clock from their casing using a small screwdriver. 3, Remove the rear wall supports. 4. Remove the (entrance) grip. 5. Remove the rear wall lining. Pay attention to the connectors for the cab heater sensor and lighting. tnstaling the roar wail ining Fit the rear wall using the panel clips. Pay attention to the connectors for the cab heater sensor and lighting. 2. Fitthe (entrance) grip. 3, Fitthe supports to the rear wall. 4, Fitthe thermostat and clock if applicable. ©0210 Removal and installationINTERNAL CAB COMPONENTS 1 Removal and installation ‘LF45/55 series ~ 4.17 REMOVAL AND INSTALLATION, ROOF LINING Removing the root ining Remove the dashboard. 2. Remove the steering wheel Note: ‘When working on the upholstery make sure hands are clean or wear gloves. Remove the roof console. Remove the rear window cover, if applicable. Remove the panel clips from the roof ining. Remove the cover panels from the A-pillar. Partially remove the door rubbers. Remove the entrance grips if the vehicle has a sleeper cab. 8. Remove the connectors from the root console lighting. Installing the roo ning Fit the roof lining from the co-driver's side. 2. Fitthe lighting connectors. Fit the roof console. Fit the entrance grips. Fit the door rubbers. Fitthe panel clips. Fit the rear window cover. Fit the cover panels in the A-pil Fit the steering wheel Fit the dashboard, PEPNaane 4-36 RAE ©02101 LF45/55 series 4.18 REMOVAL AND INSTALLATION, SIDE WALL LINING Removing the side wall lining Note: When working on the upholstery make sure hands are clean or wear gloves. 1. lemove the caps from the door pillar. 2. Remove the steo! plates that are fixed to the rear wall. 3. Ifthe vehicle has a sleeper cab, the storage ‘rays under the bed need to be removed. 4, Remove the panel clips and the side wall ining. Fit the side wall ining using the panel clips. 2. Itapplicable, fit the storage trays. 3. Fitthe steel panels to the side walls. 4, Fitthe covers in the door pillar. 4.19 REMOVAL AND INSTALLATION, STORAGE TRAYS (SLEEPER CAB) eeroving the storage trays Remove the wooden bed base. 2. Remove the rear wall panel and the side panels. 3. Remove the attachment bolts in the bottom of the storage trays. 4, Remove the storage tray. Instaing the storage trays Put the storage trays in place. 2. Fitthe attachment bolts in the bottom of the storage trays. 3, Fitthe rear wall panels and the side panels. 4. Fitthe wooden cover. ©0210 INTERNAL CAB COMPONENTS. Removal and installation 437INTERNAL CAB COMPONENTS 1 Removal and installation LF45/55 series ©0210 ~1 CAB HEATING LF45/55 series Contents CONTENTS Date = 0210 0210 0210 = 0210 0210 2 0210 0210 0210 0210 * 0210 1. SAFETY INSTRUCTIONS 2 GENERAL . 2.1 System description of heater, heater control - 3. REMOVAL AND INSTALLATION ..... : 3.1. Removal and installation, interior fer” <=. 3.2 Removal and installation, heater unit. 3.3 Removal and installation, heater controi panel. 344 Femoval and instalation, heater motor... 5 36 Removal and installation, series resistor. Removal and installation, heater radiator |. ©0210CAB HEATING 1 Contents LASSE series. = A ~ ~ 2 Rar ©0210fn 1 LFA5/55 series 1. SAFETY INSTRUCTIONS “The ar conditioning system may only be opened and filed by 2 specialist. Furthermore, many countries require official certification to carry out such activities. ©0210 CAB HEATING Safety instructions 141CAB HEATING 1 Safety instructions 12 LF45/55 series ©0210 ~1 CAB HEATING LF45/55 series General 2. GENERAL 2.1 SYSTEM DESCRIPTION OF HEATER, HEATER CONTROL ‘The heater is installed in the central console as a complete unit. ‘The unit contains all control valves, control handles and switches needed for ventitation and heating. ‘There are two models: hheating/ventiiation system hheating/ventiiation system combined with air conditioning. ‘The control panel has three rotary knobs. Knob 1 Five-position switch to control fan speed. 472734 Tee poston evict contol tn peed wth rootcloion ae 2 oe Knob 2 B Air outlets in the cab. we —A = postin (7 W windscreen (defroster) windsoreen and log area leg area {eg area and dashboard c i dashboard moo@>eCAB HEATING 1 General LFA5/55 series knob 3 ‘Temperature controt offers a continuously variable supply of hot air rom 0 to 100%. ‘Air distribution ‘Optimal air distribution in the cab can be achieved by means of knob 2 in combination with the rotating and adjustable vents on the central console and at the sides of the dashboard, 22 ©02101 CAB HEATING ‘LF4S/S5 series Removal and installation 3. REMOVAL AND INSTALLATION 3.1 REMOVAL AND INSTALLATION, INTERIOR FILTER Removing the interior fitter 1. Open the cab grille. 2. Remove the attachment bolts (1) from the grille on the underside ofthe fiter casing. 3. Open the grille (2) and remove the interior filter. Installing the Interior fitter 1. Fitthe interior fiter, close the grille (2) and fit the attachment bots (1). 2. Close the cab grille. ©0210 a4CAB HEATING 1 Removal and installation LF45/55 series 3.2. REMOVAL AND INSTALLATION, HEATER UNIT Removing the heater unit 1. Take the cover panel out of the window frame, 2. Remove all dashboard panels on the underside. 3. Remove the upper cover panel 4. Remove the dashboard panels on the ‘co-driver's side. Remove the garish ‘moulding around the instrument panel. 5. Remove the attachment bolts from the ‘mounting plate at the front of the heater. Remove the mounting plate and the upper attachment bots. 6. Take the heater control out of the radio ppanel and place it on the left-hand side of the heater. 7. Remove the heater unit connectors. 8. Remove the heater unit air ducts. 9. Remove the upper attachment bolts from the heater unit. 32 Roe ©0210 ~~ 1 CAB HEATING LF45/55 series Removal and installation 10. Remove the interior fiter casing attachment bots 1) and remeve thee er casing 11, Remove the attachment bolts from heater unit (1). 12, Partially drain the coolant. 18. Remove the heater hoses (2). 14. Remove the cover (2) atthe front by pressing the retainers (1) aside. ©0210 Bae 33CAB HEATING Removal and installation 15. Remove the connectors (1), press the retainers (2) inwards and push the holder ‘complete with connectors inside. Note: If the vehicle has air conditioning fitted, ‘work on the air conditioning must be d by a qualified person. 16. Ifrelevant, empty the airconditioning unit. 17. Remove the air conditioning pipes. 18. Remove the coolant hoses and seal the ‘openings on the heater unit to prevent the coolant sping out into the cab. 19. Remove the heater unit, 34 ©02101 CAB HEATING ‘LF45/55 series Removal and installation Installing the heater unit ‘+ Fite heter unt Pua the holder forthe ‘connectors into the 2. Fitthe attachment bolts (1) and the heater hoses (2), 3. Fit the interior ter casing (2). Secure it with the attachment bolts (1). 4. Connect the air conditioning pipes. 5. Fit the heater unit air ducts. e210 pat 35CAB HEATING 1 Removal and installation LF45/55 series, 6. Fitthe connector holder via the inside. Push 2 itinto the retainers. (2). 3 7. Fitthe connectors (1). ‘8. Tighten the upper attachment bolts. ‘9. Tighten the attachment bolts at the front. ©02101 CAB HEATING LF45/55 series Removal and installation 10. Fitthe heater contol in the racio panel. Fit the garnish moulding around the instrument panel. 11. Reinstall removed dashboard panels. 12. Top up the cooling system. 13. Fill the air conditioning unit, if necessary. ©0210CAB HEATING 1 Removal and installation ‘LF45/55 series 3.3. REMOVAL AND INSTALLATION, HEATER CONTROL PANEL, Removing the heater control panel 1, Remove instrument panel cover panel. 2. Remove the control panel from the radio panel by pushing the right and left clips out. ny 3. Putthe selection knob (1) in the windscreen demister position. Mark the position of the Cable. Remove the clip and take the cable ut of the control panel. 4, Set the temperature selection knob (2) to ‘the hottest position. Mark the position of the cable. Remove the clip and take the cable Out of the control panel, 5. Set the heater motor selection knob (3) to the stop” position. Mark the position of the ‘cable. Remove the clip and take the cable ‘out of the control panel 6. If applicable, remove the connector from the air conditioning button. 7. Remove the control panel. 38 RAE ©0210 ~1 CAB HEATING LF45/55 series Removal and installation Inetaling the heater control pene! applicable, fit he connector ofthe air conditioning button. 2. Fitthe control cables and secure them with the lips atthe appropriate markings. Make ‘sure that the selection knobs are in the correct postion. 3. Fitthe control panel and push it into the retai 4, Fitthe instrument panel cover panel and ‘secure it with the attachment bolts. ©0210 Bae 39CAB HEATING 1 Removal and installation ‘LF45/55 series 3.4 REMOVAL AND INSTALLATION, HEATER MOTOR Removing the heater motor 1, Remove the fire extinguisher, if applicable. 2. Remove the dashboard panel on the engine tunnel 3. Remove the ashtray and the ashtray holder. ‘Take out the cigarette lighter connector and remove the ashtray lighting, 4. Remove the connectors from the heater cover. 5. Remove the cover attachment bolts and put the cover aside. 6. Remove the connectors from the series resistor. lt applicable, remove the connectors from the air conditioning thermostat. 7. Remove the cover. 3-10 pase ©0210 ~1 CAB HEATING LFA5/S55 series Removal and installation 8. Remove the heater motor attachment bolts. 9. Remove the heater motor. Installing the heater motor 1. Install the heater motor and secure it with ‘attachment bolts. 2. Fitthe connectors to the series resistor. ©0210 par 3-11CAB HEATING 1 LF4S5/55 series 3. applicable, fit the connectors to the air conditioning thermostat. 4, Filthe cover and secure it with the attachment screws. 5. Fitthe connectors to the cover. 6. Fitthe dashboard panel to the engine tunnel. 312 pas ©02101 CAB HEATING LF45/55 series Removal and installation 3.5 REMOVAL AND INSTALLATION, SERIES RESISTOR Removing the series resistor. 1. Remove the fire extinguisher, it applicable. 2. Remove the dashboard panels on the underside. 3. Remove the attachment screws from the series resistor and remove the series resistor from the cover. 4. Detach the connectors from the series resistor and remove the series resistor. 3413 e210CAB HEATING 1 Removal and installation LF45/55 series Installing the series resistor 1. Fitthe connector to the series resistor. 2. Fitthe resistor and secure it using the attachment screws. 3. Fitthe connector to the cover. 4. Fitthe dashboard panels on the underside. 3-14 RAE ©0210 ~1 CAB HEATING LF45/55 series Removal and installation 3.6 REMOVAL AND INSTALLATION, HEATER RADIATOR Removing the heater radiator 1. Remove the heater unit. 2. Remove the cover. 1 00689 3. Detach the connectors from the air ‘conditioning thermostat and remove the series resistor. 4, Remove the heater motor. ©0210 Bez 3-15CAB HEATING Removal and installation 5. Remove the attachment bolts from the air Conditioning thermostat. Remove the capillary tube from the evaporator. 6. Remove the fastening clip from the control Cable and remove the heater valve. 7. Remove the attachment bolts from the heater valve holder. 8. Remove the O-rings. 3416 Bae ©02101 CAB HEATING LF4S/S5 series Removal and installation 9. Remove the attachment bolt from the heater pipe fastening. 10. Remove the heater pipes and remove the O-rings. 11, Remove the radiator attachment bolts. ©0210 par 347CAB HEATING Removal and installation 12. Push the retainer aside. 18. Remove the radiator. 1 ‘LF45/55 series ©02101 CAB HEATING ‘LF45/S5 series Removal and installation Inetaling the heating racator Install the heater radiator inthe heating unit 2. Press the heater radiator into the retainer. 3. Fitthe heater radiator attachment bolts. 4. Fitrew O-rings and ft the heater pipes. 5 Secure the heater pipe with the attachment bot. 6. Fitthe heater valve holder and secure it using the attachment bolts. 7. Fitthe control cable to the heater valve and ‘secure it using the fastening clip. 8. Install the heater motor. 9. Fitthe air conditioning thermostat ‘connectors and the series resistor. 10, Fitthe heater motor cover. 11, Fitthe heater unit. ©0210 349CAB HEATING 1 Removal and installation LFA5/55 series 3-20 Bae ©02101 EXTERNAL CAB COMPONENTS LF45/55 series Contents CONTENTS Date 4. SAFETY INSTRUCTIONS .. 0210 2 GENERAL . 0210 21 Description of exterior mirrors. 0210 2.2 Description of windscreen wiper and washers 23 Description of headlight leveling . 9. INSPECTION AND ADJUSTMENT ......... 3.1 Inspection and adjustment, headlights 4, REMOVAL AND INSTALLATION . 4.1, Removal and installation, windscreen wiper system . 4.2 Removal and installation, entrance step grille 13 Removal and instalation, entrance stop support. Removal and installation, door . Removal and installation, comer piece Removal and installation, lattice grille. 4.7 Removal and installation, grille . 4'8 Removal and installation, lattice of headlight cover panel 4.9 Removal and installation, headlight cover panel ....... 4.10 Removal and installation, roof hatch . . : 4.11 Removal and installation, bumper .. 4.12 Removal and installation, windscreen 4.13 Removal and installation, rear window glass 4.14 Removal and installation, door glass 4.18 Removal and installation, exterior mirror gi 4.18 Removal and installation, exterior mirrors compl 4.17 Removal and installation, pavement mirror... 4.18 Removal and installation, dead angle exterior mirror 4.19 Removal and installation, headlight . 4.20 Removal and installation, headiight bracket 4.21 Removal and installation, headiight leveling control . 4.22. Removal and installation, mudguard assembly . 0210 0210 0210 0210 0210 0210 0210 0210 0210 2) 0210 10210 1 0210 1 0210 1 0210 210 0210 210 210 0210 0210 0210 0210 0210 0210 0210 210 0210 ©0210 Bee 1EXTERNAL CAB COMPONENTS 1 Contents LF45/S5 series 2 par ©0210 ~1 LFAS/S5 series 1. SAFETY INSTRUCTIONS General ‘The cab is equipped with a hydraulic titing gear. ‘The pump is located on co-driver's side at the rear of the cab. The cab locks are opened hydraulically during pumping. Before titing the cab, make sure that the doors are closed, that there are no loose items in the ccab and that the gear lever is in neutral. Tit the Cab fully forward if work is to be carried out undemeath the cab. You can stop the cab titing forward at any timo by turing the gock to the rere thing poston han wottng on ait ab (or (By marelennes wong, Sprappalning or apping tuvon coatings), be sure to cover the piston rod of the lifting cylinder. Welding spatter and paint on the piston rod will inevitably cause damage to the oll seal. pection after a collision re tiking the cab after a collision, check the ‘cab rests, the cab hinges and the attachment of the liting cylinder to the chassis member and ‘cab for cracks. A If the vehicle has been involved in a collision, the cab must under no circumstances be tilted without due precautions. The end stop in the lifting cytinder may be damaged, ‘which might cause the cab to shoot Past its end stop. If possible, suspend the cab in slings and put a stand in front of the cab. Make sure that there is. ‘no one in front of the cab while it is being tited. ©0210 EXTERNAL CAB COMPONENTS Safety instructionsEXTERNAL CAB COMPONENTS Safety instructions Replacing the lifting cylinder After a collision, always check the lifting cylinder for internal damage. Replace the lifting cylinder if damaged or if you are in doubt as to the its condition. ‘Always replace the cylinder if one of the folowing points has occurred during a coliion the cab has been pulled out of the cab locks, B. the cab locks have been deformed or damaged, C. the rear cab springs have been deformed or damaged. 12 1 LFAS/55 series ©0210 ~1 EXTERNAL CAB COMPONENTS ‘LF45/55 series General 2. GENERAL 2.1 DESCRIPTION OF EXTERIOR MIRRORS All exterior mirrors and exterior mirror arms Used are factory set for average driving ‘conditions. ‘After the superstructure has been ‘constructed on the vehicle, its required by law that all exterior mirrors and exterior mirror arms ‘should be re-adjusted in accordance with EC Directive 88/321. This critical adjustment ‘depends entirely on the width of the vehicle's superstructure. ‘To ensure proper adjustment of the exterior mirror/exterior mirror arms as provided for in the Directive, itis important to follow all adjustment procedures closely. Exterior mirror classification This section describes the different types of Vehicle exterior mirrors according to the standard EC exterior mirror classification. The following vehicle exterior mirror categories apply Main exterior mirror “Category 4" = Wide angle exterior mirror "Category 5" - Close-up exterior mirror Note: ‘Category 1 (inside) and category 3 (exterior mirrors are Intended for passenger cars. “The exterior mirror consists of convex glass and an aerodynamically shaped mirror housing. The main exterior mirror and wide-angle exterior mirror (only on co-driver side) are fitted to D-shaped arm on the door. The pavement is attached to the upper part of the door on a separate bracket. ‘The exterior mirror bracket returns to its original postion fit gets lapped back. On several models there is an extra exterior miror (apart from a pavement mirror) on co-driver side giving the driver a better view of the drawn vehicle. or ©0210 per 24EXTERNAL CAB COMPONENTS General ‘The main exterior mirror heating and the windscreen heating, can be turned on by a switch on the dashboard. When the exterior mirror heating is turned on, the warning lamp in the switch lights up. ‘The exterior mirrors can be divided into: = non-heated exterior mirrors = heated exterior mirrors (except for pavement mirror) in combination with Windscreen heating 2.2 DESCRIPTION OF WINDSCREEN WIPER AND WASHERS ‘There are two windscreen wipers which are ‘equipped with nozzle tips, each of which has three spray nozzles. The high-pressure pump {or this washing system abuts the storage tank. ‘The washers are underneath the headiights. The filer opening of the storage tank for the windscreen washers and possibly the headlight washers is lcated in the stepwel on driver's e. 2.3 DESCRIPTION OF HEADLIGHT LEVELLING ‘The cab is equipped with an internal device for adjusting the angle of the headlight beam. Control is by a rotary knob located in the cab. ‘The knob is situated on the dashboard to the right of the steering wheel, ‘The headlights are levelled by means of electric motors located at the bottom of the headlight unit, 22 Par 1 ‘LF45/55 series ©02101 EXTERNAL CAB COMPONENTS LF45/55 series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 INSPECTION AND ADJUSTMENT, HEADLIGHTS Note: Use adjustment equipment to check and adjust the headlights. ‘Adjustment, headiamps When adjusting the headlights, check that: ‘the vehicle is unladen and the tyres are inflated to the specified pressure. = the vehicle is standing on a flat and level surface. = inside the cab the height adjustment of the headlights is in "0"-position. 2, The headlight can be adjusted by four knurled knobs at the rear of the headlight housing; main beam and dipped beam can bo adjusted separately: ‘To adjust the dipped beam horizontally, tum knob 1. = To.adjust the dipped beam vertically, tum knob 2. + Toadjust main beam horizontally, turn knob 3. = Toadjust the main beam vertically, turn knob 4. ©0210 eae 34EXTERNAL CAB COMPONENTS Inspection and adjustment 3. As clear headlight glass is used the image of the asymmetrical light beam deviates slightly from the usual image. The beam of light is not a straight line that slants. ‘upwards, but is slightly convex. 4, Adjust the headlight in such a manner that the intersection of the convex and the horizontal light beam coincides with the intersection of the asymmetrical diagonal and the horizontal adjustment line. It does ‘not matter that the light beam convex is above the asymmetrical diagonal. 32 1 LF45/55 series ©0210 ~1 EXTERNAL CAB COMPONENTS ‘LF45/55 series Removal and installation 4, REMOVAL AND INSTALLATION 4.1 REMOVAL AND INSTALLATION, WINDSCREEN WIPER SYSTEM Notes: Before replacing the wiper linkage, the following points must be observed. It the bearings of the wiper linkage are worn, replace them as well as the linkag Use the correct tools when removing old linkage in order to avoid damaging the seals. Use FINA Ceran-grease for new linkage. ‘When fitting new linkage, never hit the sealing Covers of the linkage with a hammer or other hard object. These covers are only 1 mm thick ‘and might suffer damage in this way. If the motor shaft shows evidence of axial play, replace the motor. This play will cause excessive wear to the wiper linkage. 24 ° rE = 6 | — oO - Cs x 0.08 Removing the windscreen wiper system 1, Remove the attachment nuts (1) from the windscreen wiper arms and remove the ‘windsoreen wiper arms (2) using a pulley puller (rade too). ©0210 atEXTERNAL CAB COMPONENTS. 1 Removal and installation LFAS/S5 series We 5 = i (eboRe]] 2. Remove the hose for the windscreen wiper ‘uid (1). Remove the protecting plate (2). Remove the connectors (3). Remove the attachment nut (4). Remove the attachment bolts (6) and remove the windscreen wiper mechanism. tnstaling the windscreen wiper mechanism Fit the windscreen wiper mechanism with the attachment bolts (6). Fit the attachment nuts (4). Fit the connectors (3). Fit the protecting plate (2). Fit the hose for the windscreen wiper fuid (1). 6. Putthe windscreen washer motor in the ‘neutral position by turning it on and off Quickly using the switch in the cab. 7. Fitthe windscreen wiper arms. ©02101 EXTERNAL CAB COMPONENTS LF45/S5 series Removal and installation 4.2 REMOVAL AND INSTALLATION, ENTRANCE STEP GRILLE Removing the stepwell and entrance step su 1. Remove the attachment botts (1) from the stepwell, 2. Remove the grille, Installing the stepwell and entrance step support 1. Fitthe grile, 2. Secure the grille with the attachment bolts (1). ks 00987 4.3 REMOVAL AND INSTALLATION, ENTRANCE STEP SUPPORT Removing the entrance step support 4. Titthe cab forward. 2. Remove the attachment botts (1). 3. Remove the bracket from the entrance step. Installing the entrance step support 1. Fitthe bracket. 2. Secure the bracket with the attachment bolts (1). 3. Tittthe cab back. ©0210 Bae 43EXTERNAL CAB COMPONENTS: 1 Removal and installation LFA5/55 series 4.4 REMOVAL AND INSTALLATION, DOOR Rer 1 44 |. Remove the attachment nut (1). Remove the pin (2). Suspend the door in a hoist using a "Detach the connector from the holder (3) |. Remove the fitted bolts. moving the door Remove the comer piece. Wind the door glass down, ks 00970 sling (1). Remove the cover caps (1) ‘and take the connector (2) apart. Remove the door. ©0210 ~cr 1 LF45/55 series Installing the door 1. Install the door. 2. 3, 4 lace the fitted botts and tighten them. Fitthe cover caps (1). Reassemble the connector (2) and fit tin the holder (3). Fitthe pin (2). .Fithe nut (1). EXTERNAL CAB COMPONENTS Remove the hoist and close the door glass. .Fitthe comer piece. ©0210 Removal and installation 45EXTERNAL CAB COMPONENTS, 1 Removal and installation LFA5/55 series 4.5 REMOVAL AND INSTALLATION, CORNER PIECE Removing the comer piece 1. Open the grille and remove the attachment bolts (1) 2. Open the door and remove the attachment bolts (1). 8. Remove the comer piece (2). Installing the comer piece 1, Fitthe comer piece. 2. Secure the comer piece (2) in the door post and at the front ofthe cab, using the attachment bolts (1). 3. Close the grille. 4.6 REMOVAL AND INSTALLATION, LATTICE GRILLE Removing the lattice grille 1. Open the grile. 2. Remove the attachment bolts from the lato 8. Remove the lattice. Fitting the lattice grille 1. Fitthe lattice, 2. Secure the lattice using the attachment bolts. 3. Close the grille. Ks 00901 46 Ree ©0210 ~1 EXTERNAL CAB COMPONENTS LF45/55 series Removal and installation 4.7 REMOVAL AND INSTALLATION, GRILLE Removing the grille ‘Open the grile and support it. 2. Remove the locking clips from the gas spring attachment and remove the gas springs. 3, Remove the attachment botts from the grile and remove the grille. Inetaing the grit Position the grille and secure it using the attachment bots, 2. Support the grille when open and install the {928 springs using the locking cps. 3. Close the grill. Ks 0099 4.8 REMOVAL AND INSTALLATION, LATTICE OF HEADLIGHT COVER PANEL Removing the lattice from the headlight cover pane! 1. Loosen the attachment screws (1) by "/«-of atum. 2. Remove the lattice (2). Fitting the lattice of the headlight cover pane! 1, Fitthe lattice (2). 2. Position the slot ofthe attachment screws (1) horizontally and push them in piace. ©0210 Baer a7EXTERNAL CAB COMPONENTS 1 Removal and installation LF45/55 series 4.9 REMOVAL AND INSTALLATION, HEADLIGHT COVER PANEL Removing the headlight cover panel 1. Remove the lattice from the cover panel, 2. Remove the attachment bolts (1) from behind the lattice. 3, Remove the attachment botts with nuts (3 and 4) at the rear of the headlight cover panel. 4. Remove the nuts (2). 5. Remove the attachment bolts (1) on either side and remove the covers. 6. Remove the attachment bolts (1). 7. Remove the headlight cover panel. 48 Ras ©0210 ~1 EXTERNAL CAB COMPONENTS ‘LF45/55 series Installing the headlight cover panel 1. Fitthe headlight cover panel. 2. Insert the attachment bots (1). 3. Fitthe attachment bolts and nuts (3 and 4) (on the rear side of the cover panel 4, Fitthe nuts (2). 5. Insert the attachment botts (1). 6. Fitthe cover panel. Secure it using the attachment botts (1). 7. Fitthe lattice to the cover panel. ©0210 Removal and installation 49EXTERNAL CAB COMPONENTS. 1 Removal and installation 4.10 REMOVAL AND INSTALLATION, ROOF HATCH Removing the roof hatch 1. Remove the attachment bolts from the roof hatch weather strip. 2. Remove the roof hatch weather strip. 3. Remove the roof hatch attachment bolts. 4, Remove the roof hatch. Installing the roof hatch 1. Install the roof hatch, . Tighten the attachment bolts evenly. 1. Fitthe roof hatch weather strip, |. Secure the roof hatch weather strip with the attachment bolts. sen 4-10 LFA5/S5 series ©02101 EXTERNAL CAB COMPONENTS, LF45/55 series Removal and installation 4.11 REMOVAL AND INSTALLATION, BUMPER Removing the bumper Remove the attachment bolts on the ‘underside of the bumper (1). Remove the attachment botts (2) on the top ‘of the bumper (1). These attachment bolts ‘can be reached using an open-end spanner ‘on the rear of the bumper. 3. applicable, remove the lighting connectors. Instaling the bumper Fit the bumper. 2. Position the bumper. Secure the attachment bolts (1 and 2) on the top and underside. applicable, ft the lighting connectors. ©0210 pare anEXTERNAL CAB COMPONENTS 1 Removal and installation ‘LF45/55 series 4.12 REMOVAL AND INSTALLATION, WINDSCREEN Removing the windscreen 1, Remove the grille. 2. Take the cover panel out of the window frame. 3. Remove the windscreen wiper arms. 4. Remove the plastic cover strips on the inside of the front-screen pillars (A-pillar). 5. Protect the curved areas on the outside of the windscreen frame with inen tape. Also Use tape to protect the plastic parts on the inside and the defroster openings of the heating and ventilation system. Note: ‘Take care not to damage the paint. 6. Putthe wire (special to), DAF no, 1329416) at approximately the mile of the upper and lower side ofthe lass using piers or a special pass-through {ool (special tool, DAF no. 1240458) through the sealant. Not Remove the wire pass-through tool before {iting the wire ends to the handles of the cutting wire set. 7. The length of the cutting wire should be 1.5 x the height of the windscreen, 8. Secure the handles that are part of the set, special tool (DAF no. 0499817) to the cutting wire. Kio7s 412 Rae ©02101 EXTERNAL CAB COMPONENTS, LFA5/55 series Removal and installation 9. Use tape strips to protect the glass from faling out accidentally (after the sealant has been cut through). 10. Start the cutting in the middle. Make sure the wire is kopt moving and tightly stretched all the time. i the wire gets twisted, i wil inevitably break. 11, Keep the cutting wire as close as possible to the edge of the glass. 12, Make sure the wire ends are crossed before the bottom comers are reached, 1, Take the windscreen out ofthe frame using the two suction pads, special too! (DAF no. 0484800). 14, Remove any remaining sealant in the window frame with a scraper, special tool (DAF no. 1329417). Make sure the Temaining layer of sealant has a thickness of at most 1 to 1.5 mm and that itis flat and smooth, 15. Remove frayed pieces and granules of old sealant end clean the frame thoroughly with aceaner, Important tips Pi the new windscreen i ited ata lator time, the od, uly cured sealant should be cleaned 1 minutes betore the glass Is fied, to ensure proper adhesion. = Repair any damage tothe paint on the ¥ window frame immediately withthe right sone ‘ype of paint. + Always work in a clean area. = Wear industrial gloves or use a special hhand cream. = Use paper towels or tissues instead of cleaning rags. ©0210 RAE 413EXTERNAL CAB COMPONENTS 1 Removal and installation LF45/55 series Installing the windscreen Be caraul when using cleaner. Contact wth the cleaner wil cause Skinirtaton end swatowing wil sause buming Iahetng may Zeus breathing osioge” 1. Any damage to the paint should be repaired well before the windscreen glass is placed. Use the right type of paint. 2. Make sure that the guide rail is smooth and flat (n0 major irregularities). 3. Check the windscreen for damage. 4. ‘Attach two double suction pads, special tool (DAF no. 0484800) to the outside of the glass. 6. Put the windscreen with the suction pads on ‘a completely clean workbench. 6. Fitthe rubber trimming to the glass and ‘secure it with tape on the outside of the glass. 7. Place the glass in the frame without using sealant, stating at the bottom and ensuring that it fits exactly in the frame. f necessary, fill up the rubber spacer blocks by means of Which the glass rests on the suppor blocks. 8. Mark the correct position of the glass in the ‘frame with strips of tape. (Cut through the tape in the frame. 9. Remove the glass from the frame and place the glass on the workbench, 40. Clean the glass where the layer of sealant is tobe applied. See “Technical date” 11, Clean the sealant within the frame. 414 Rae ©02101 EXTERNAL CAB COMPONENTS. LF45/55 series Applying sealant 1. For hot processing, the adhesive should be heated in an oven, special tool (DAF no. 1329416) for 60 minutes at 80°C. 2. Apply the sealant to the rubber as indicated in the diagram. There is no rubber on the Lnderside of the windscreen. Here, the seal beads must be 11 mm from the edge of the glass. 3, Take note ofthe processing time when applying the sealant. See “Technical deta’. 4, Place the sealant gun with the opening '90°/60° onto the windscreen and move it ‘evenly to build up a good layer. ‘Avoid air bubbles in the layer of sealant. Note: fa pneumatic glue gun is used for sealing (special tool DAF no 1240444) then before beginning adjust the pressure in the gun by spraying several test strips. Fring the glass For safety, open the windows to avoid Uundesirabie pressure build-up on the windscreen. 2. The glass should be taken from the ‘workbench by two persons and it should be placed in the frame in one go. Use the tape Strips to determine the correct position. 3. Make sure that the rubber windscreen trim ‘on the bottom seats properly into the frame, ©0210 pee Removal and installation 415EXTERNAL CAB COMPONENTS 1 Removal and installation 4, Use a sealant remover to remove the excess sealant immediately from the painted parts, see "Technical data’. 5. Depending on the type of sealant used (hardening time), fit straps. See “Technical data’. Protect the paint by iting linen tape in the places where the straps will ouch the paint. 6. {fapplicable, pull two strips round the ‘outside of the windscreen and the cab pillar. Put strips of wood or Tempex underneath to avoid damage. 7. Let the sealant harden. See “Technical data’. 8 Remove from the cab body all the tape used for protection and marking. 9. Clean the entire windscreen and the parts ‘of the cab body which have been fouled during installation of the windscreen using a ‘lass cleaner. 10, Fitthe A-pillar trimming panels in the cab. 11. Fittthe cover panel to the window frame. 12, Fitthe windscreen wipers and adjust them. 18. Fit the grille 14, Ifthe vehicle is fited with an airbag, apply a ‘new airbag sticker to the windscreen, 416 Par ‘LF45/55 series ©02101 EXTERNAL CAB COMPONENTS ‘LF45/55 series Removal and installation 4.13 REMOVAL AND INSTALLATION, REAR WINDOW GLASS Removing the rear window glass Remove the cover panel attachment bolts. Remove the cover panels. 2. Attach a suction pad (DAF no. 0484800). 3. Put the wire (special tool, DAF no. 1929416) at approximately the middle of the upper and lower side of the ‘glass using pliers or a special pass-through {ool (special tool, DAF no. 1240458) ‘through the sealant. Note: Remove the wire pass-through tool before fiting the wire ends to the handles of the cutting wire set. 4. The length of the cutting wire should be 1.5 x the height of the window. 5. Secure the handles that are part of the set, ‘special tool (DAF no. 0499817) to the cutting wire. 6. Use tape strips to protect the glass from falling out accidentally (after the sealant has been cut through). 7. Start outing in the middle. ‘Make sure the wire is kept moving and tightly stretched all the ime. Ifthe wire gets twisted, it wil inevitably break. 8. Keep the cutting wire as close as possible to the edge of the glass. 9. Make sure the wire ends are crossed before the bottom comers are reached. 10. Take the glass out of the frame using a ‘suction pad, special too! (DAF no. 0484800). ©0210 par 417EXTERNAL CAB COMPONENTS, 1 Removal and installation 11. Remove any remaining sealant in the window frame with a scraper, special toot (DAF no. 1329417). Make sure the Temaining layer of sealant has a thickness Of at most 1 to 1.5 mm and that itis flat and ‘smooth. 12, Remove frayed pieces and granules of old sealant and clean the frame thoroughly with a cleaner. Fiting the rear window glass necessary, smooth off spare sealant. 2. Apply the adhesive (1) as shown. 8. Fitthe spraying nozzle to the cartridge and ‘apply the sealant to the window, spraying as evenly as possible. 4. Place the sealant gun with the opening '90°/60° onto the windscreen and move it evenly to build up a good layer. 5. Avoid air bubbles in the layer of sealant. Note: a pneumatic glue gun is used for sealing (special tool DAF no 1240444) then before beginning adjust the pressure in the gun by spraying several test strips. 6. Pay attention to the processing time, see "Technical data’ 7. Fitthe rear window glass and press it into the frame. Secure the glass in several places with strips of tape around 20 em long. Open the door windows to prevent pressure in the cab. 418 LFA45/55 series 9mm Ks on7e ©02101 EXTERNAL CAB COMPONENTS LF45/55 series Removal and installation 8. Let the sealant harden. See “Technical data’. 9. Remove from the cab body all the tape used for protection and marking. 10. Clean the entire window and the parts of the ‘cab body which have been fouled during installation of the window glass using a glass cleaner. 4.14 REMOVAL AND INSTALLATION, DOOR GLASS Removing door glass 1. Remove the complete window mechanism, 2. Tiltthe door glass (1). 3. Remove the door window from below. Installing door glass 1. Fitthe door window from below. 2. Fitthe window mechanism. _ 1 krone ©0210 pase 419EXTERNAL CAB COMPONENTS 1 Removal and installation ‘LF45/55 series 4.15 REMOVAL AND INSTALLATION, EXTERIOR MIRROR GLASS Removing miror glass 1 Push in the cover (1) of the mirror housing {6) at ho notches. Remove the cover (1) from the exterior mirror housing (8). 2. Disconnect the electrical exterio adjustment connector (7), if applicable. 3. Disconnect the exterior mirror heating connector (8). 4, Remove the attachment botts (2) from the ‘clamping brackets (3). Mark the position. Remove the outside mirror housing (5). 5. Remove the attachment bolts (4) from the mirtor glass holder (8). Push the mirror lass holder (8) out of the mirror hot ©. 6. IK fitted, remove the attachment screws (6) from the electrical exterior mirror adjustment (7). Mark the position of the electrical mirror adjustment (7). lemove the electrical miror adjustment (7) trom the mirror glass holder (8) 7. Place the exterior mirror glass holder (8) in ‘hot water bath of approx. 80°C. Allow the mirror glass holder (8) and mirror (10) to heat for fifteen minutes. . 8. Wear isolating gloves to prevent burns. ‘Take the exterior mirror glass holder (8) out of the hot water bath. Carefully press one side of the mirror (10) out of the mirror glass holder (8). 9. Carefully remove the exterior mirror (10) from the mirror glass holder (8). 4-20 Bar ©02101 EXTERNAL CAB COMPONENTS LF45/55 series Removal and installation Instaing exterior mirror glass 1294 56 lace the exterior miror glass holder (8) in ‘a hot water bath of approx. 80°C. Allow the mirror glass holder (6) to heat for fiteen minutes. 2. Wear isolating gloves to prevent burns. ‘Take the exterior mirror glass holder (8) out of the hot water bath. Insert the wires of the clectical exterior mirror heating (8) through the grommet in the exterior mirror glass holder (8). 3. Place one side of the mirror glass (10) in the groove of the mirror glass holder (8). Press the edges of the mirror glass holder (@) carefully over the mirror glass (10). 4. Allow the mirror glass holder (8) to cool down. If applicable, ft the electrical exterior mirror adjustment (7) tothe miror glass holder (8), Using the attachment bolts (6). Note the fiting positon. 6. Fitthe exterior mirror glass holder (8) in the ‘mirror housing (6) using the attachment bolts (4). Note the fiting position and the electrical connectors. 7. Fitthe mirror housing (6) to the mirror arm, using the attachment bolts (2) and the clamping brackets (3). 8. applicable, connect the electrical ‘connectors of the electrical mirror adjustment (7) and the mirror heating (8). 9. Fitthe cover (1) to the exterior mirror housing (6). ©0210 4-21EXTERNAL CAB COMPONENTS 1 Removal and installation ‘LF45/55 series 4.16 REMOVAL AND INSTALLATION, EXTERIOR MIRRORS COMPLETE WITH ARMS Removing the exterior mirror assembly 1. Remove the attachment bolts (1) and remove the exterior mirror assembly with the covers (2). 2. Remove the connector (1). 3. Remove the exterior mirror assembly with the covers. Installing the exterior mirror assembly 1, Fitthe connector (1). 2. Fitthe exterior mirror assembly with arm and the covers. 3. Secure the mirror with the attachment bolts. Ensure that the rubber O-rings are fitted between the cover and the door. 422 Bee ©02101 EXTERNAL CAB COMPONENTS LF45/S5 series Removal and installation 4.17 REMOVAL AND INSTALLATION, PAVEMENT MIRROR Removing the pavement mirror 1. Remove the attachment bots (1) and remove the pavement miror with the cover Plate (2). Installing the pavement mirror 1. Fitthe pavement mirror and the cover pie ae secare 8h to ecto 8 (1). 4.18 REMOVAL AND INSTALLATION, DEAD ANGLE EXTERIOR MIRROR Removing the dead angle exterior miro, ‘Qpen the cab gre. pen te co-tiver's 2. Remove the attachment bolts from the comer piece. Remove the comer piece. Disconnect the dead angle exterior mirror | heating connector. 5. Remove the attachment bolts (1) from the dead angle exterior mirror. 6. Remove the dead angle exterior mirror. Instaling the dead angle exterior miror Fit the dead angle exterior mirror using the attachment bolts (1).. 2. Connect the dead angle exterior mirror heating connector. 3. Fitthe comer piace using the attachment bots. ©0210 eae 423EXTERNAL CAB COMPONENTS: 1 Removal and installation LFAS5/55 series 4.19 REMOVAL AND INSTALLATION, HEADLIGHT Removing headlight Remove the headlight cover panel 2. Remove the attachment bolts (1) on the front of the headlight 3. Pullthe headlight forward and disconnect the connectors at the rear. 4, Remove the headlight. Instaling heatight ‘Connect the headlight. 2. Hook up the rubber bulge inthe recess on Ki01 160 the headlight bracket. 3. Secure the headlight with the attachment bolts (1) a the front. 4, Fitthe headlight cover panel. 4.20 REMOVAL AND INSTALLATION, HEADLIGHT BRACKET Removing headlight bracket 1. Remove the headlight cover panel. 2. Remove the headight. 8. Remove the attachment botts, 4, Remove the headlight bracket. Instaling headlight bracket Fit the headlight bracket. 2. Secure the headlight bracket with the attachment bolts. 3. Place the headlight in position. 4. Fitthe headlight cover panel. 424 PAE ©0210 ~- 1 EXTERNAL CAB COMPONENTS, ‘LFAS/S5 series Removal and installation 4.21 REMOVAL AND INSTALLATION, HEADLIGHT LEVELLING CONTROL Removing headlight levelling contro! 1. Tithe cab forwards. 2, Remove the connectors from the headlight leveling contro. 3. Remove the headlight leveling control by ‘turning it fully anti-clockwise out ofthe back of the headlight (atthe rear). Installing headlight levelting control 1. Fitthe headlight levelling control by ‘screwing It clockwise into the bayonet catch. 2. Fit the headlight levelling connector. 3. Titthe cab back. 4.22 REMOVAL AND INSTALLATION, MUDGUARD ASSEMBLY Removing mudguard assembly 1, Tithe cab forwards. 2. Remove attachment botts and nuts (Vand). 3. Remove the mudguard assembly. Installing mudguard assembly 1. Fitthe mudguard assembly. 2. Fitthe attachment bolts (1 and 2). 3. Tittthe cab back. ©0210 por 4-25EXTERNAL CAB COMPONENTS 1 Removal and installation ‘LFAS/S5 series ©0210 ~1 CAB SUSPENSION LF45/55 series Contents CONTENTS Date 1, SAFETY INSTRUCTIONS: on 210 2, GENERAL . 0210 24 Cab suspension . + 0210 3. INSPECTION AND ADJUSTMENT .. 0210 3.1 Inspection and adjustment, cab height + 0210 4, REMOVAL AND INSTALLATION . 4.1. Flemoving the cab stabiliser ... 4.2 Removal and installation, front spring suspension cab support. 4.3 Removal and installation, cab front rubber suspension support - 4.4 Removal and installation, silent blocks of front spring suspension - 0210 +0210 0210 o2t0 cab support . . teseeress - 0210 4.5 Removal and installation, silent block of cab front rubber suspension support . 48 210 4.6 Removal and installation, col spring front suspension - 410....2 0210 4.7 Rlemoval and installation, rear coil spring suspension - 2 4912007 0210 4.8 Removal and installation, cab locking mechanism. 2 442005) 0210 4.9 Removal and installation, complete cab .... 5 418.00.) 0210 ©0210CAB SUSPENSION 1 Contents LF 45/55 series ©0210 ~1 LF45/55 series 1. SAFETY INSTRUCTIONS General ‘The cab is equipped with a hydraulic titing gear. ‘The pump is located on co-driver’s side at the ‘ear of the cab. The cab locks are opened hydraulically during pumping. Before titing the cab, make sure that the doors are closed, that there are no loose items in the ‘cab and that the gear lever is in neutral. Tit the ‘cab fully forward if work is to be carried out ‘underneath the cab. You can stp the cab ting forward A) sary tine by timing tne sock to the reverse ting poston. When working ona tite cab (for (A) mameie wos wetsing, spray plating or appiing bitumen coatings), be sure to cover the piston rod of the lifting cylinder Welding spatter and paint on the piston rod will inevitably cause damage to the oll seal. Inspection after a collision Before titing the cab after a colision, check the cab rests, the cab hinges and the attachment of the liting cylinder to the chassis member and ‘cab for cracks. It the vehicle has been involved in a AA, iaiision tn cab must unser no Sreurtances bo tiled without due precautions, The end stop in ine fing evindor may be camaged, which might cause the cab to shoot peated sop, If possible, suspend the cab in slings and put a ‘stand in front of the cab. Make sure that there is no one in front of the cab while it is being tilted, ©0210 CAB SUSPENSION Safety instructions 11CAB SUSPENSION Safety instructions Replacing the lifting cylinder After a collision, always check the iting cylinder for internal damage. Replace the iting cylinder fit is damaged or it Yyou are in doubt as to its condition. ‘Always replace the cylinder if one of the folowing pont tas occured during 2colision 8. c 12 the cab has been pulled out ofthe cab looks, the cab locks have been deformed or damaged, the rear cab springs have been deformed ‘or damaged. 1 ‘LF45/55 series ©02101 CAB SUSPENSION LF45/55 series General 2. GENERAL 2.1 CAB SUSPENSION ‘The cab is attached to the chassis at four
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